CS-60 User Manual DL..
Contents
1. MAINTENANCE 2 zc REREYeerEC ER kapas Rd Rs CS 60 User s Manual IMPORTANT SAFETY INSTRUCTIONS Carefully read these instructions and the charging instructions in your vehicle owner s handbook before charging your electric vehicle The following symbols may be found in your handbook or on labels affixed to your conductive charge station Note This means pay particular attention Notes contain helpful suggestions Caution This symbol means be careful You are capable of doing something that might result in damage to equipment Warning This symbol means danger You are in a situation that could cause bodily injury Before you work on any AN electrical equipment be aware of the hazards involved with electrical circuitry and standard practices for preventing accidents Safety Guidelines Use this charge station to charge electric vehicles equipped with a conductive charge port only See the vehicle s owner s handbook to determine if the vehicle is equipped with a conductive charge port e Make certain the charge station s supply cable is positioned so it will not be stepped on tripped over or otherwise subjected to damage or stress There are no user serviceable parts inside Refer to the Customer Support section in this manual for service information Do not attempt to repair or service the charge station yourself Do not operate your charge station with a visibly damaged supply cable2. Terminal Torq in lbs Square D 8910DPA52 45 Service Ground Lug 40 USE gt 75 C Wire Page 11 CS 60 User s Manual Warning Local electrical codes must always be followed when installing the grounding stake The following diagrams illustrate the 3 service transformer secondary connec tions most common in the United States Figure 3 220 240V Single Phase L1 120V NEUTRAL NOT USED 240V 120V L2 GND LLT Figure 4 208V 3 Phase Wye Connected L3 NOT USED iN L1 gt TY 208V NEUTRAL NOT USED 120V L2 GND FTT Page 8 Note CS 60 User s Manual With a wye connected secondary any two of the legs can be used to provide 208V to the CS 60 For example L1 amp L2 or L1 amp L3 or L2 amp L3 Leave the unused leg open Do not connect it to a Neutral bar or to Ground Be sure the center point is grounded to earth somewhere in the system Figure 5 240V 3 Phase Delta Connected with center tap on one leg L1 120V S ov 120V L2 GND Caution With the delta connection one leg must be center tapped and only the two phases on either side of the center tap can be used The two phases must both measure 120V to neutral The third line L3 of the delta is 208V with respect to neutral and is sometimes referred to as a stinger Do not use this third line Consult the transformer manufacturer s literature to be su
3. or charge station Contact your Service Representative for service immediately Refer to the Customer Support section in this manual for information on the Service Representative in your area Page 1 CS 60 User s Manual This limitation applies to damages of any kind including any direct or indirect damages lost profits lost saving or other special incidental exemplary or consequential damages whether for breach of contract tort or otherwise or whether arising out of the use of or inability to use the product even if ClipperCreek or an authorized ClipperCreek representative or dealer has been advised of the possibility of such damages or of any claim by any other party Some states do not allow the exclusion or limitation of incidental damages for some products so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state To obtain warranty service Call your nearest authorized Service Representative or ClipperCreek at the above number You will receive information as to how service for the product will be provided If you mail or ship the product in for service you must insure the product prepay all shipping charges and properly pack it for shipment in its original shipping container or its equivalent You are responsible for all loss or damage that may occur in transit You must provide proof of purchase of the
4. follow the SAE J1772 standard for communica tion with the charging station can inform the CS 60 that they require an exhaust fan The CS 60 is not equipped to control ventilation fans If an exhaust fan is requested the CS 60 will not charge the vehicle If this function is required ask your ClipperCreek representative for information on other products which have the exhaust fan control feature A Caution DO NOT charge your vehicle indoors if it requires ventilation Contact your Service Representative for information 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 and 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 such as digital phones RF communications equipment etc could affect operation If interference to your charge station is suspected we suggest the following steps be taken before consulting your ClipperCreek Sales and Service Representative for assistance A 1 Reorient or relocate nearby electrical appliances or equipment during charging 2 Turn off nearby electrical appliances or equipment during charging Caution Changes or modifications to
5. improper installation or use including but not limited to improper connections with peripherals external electrical faults accident disaster misuse abuse or modifications to the product not approved in writing by ClipperCreek Any service repair outside the scope of this limited warranty shall be at applicable rates and terms then in effect All other express and implied warranties for this product including the warran ties of merchantability and fitness for a particular purpose are hereby dis claimed Some states do not allow the exclusion of implied warranties or limitations on how long an implied warranty lasts so the above limitation may not apply to you If this product is not as warranted above your sole and exclusive remedy shall be repair or replacement as provided above In no event will ClipperCreek any of its authorized sales and service representatives or its parent company be liable to customer or any third party for any damages in excess of the purchase price of the product Page 17 CS 60 User s Manual Warning Turn off input power to your charge station at the circuit breaker panel before servicing or cleaning the unit e VENTILATION Some electric vehicles require an external ventilation system to prevent the accumulation of hazardous or explosive gases when charging indoors Check the vehicle s owner s handbook to determine if your vehicle requires ventilation during indoor charging Note Those vehicles which
6. known just by looking at the panel lights and comparing them with table 1 on page 4 Page 3 CS 60 User s Manual Load Management Inputs If your unit has been configured for Off Peak Charging the Green CHARGING light may be blinking after you plug in the cable and the contactor may not close This means that a timer or other device has been connected to the Load Management input and charging will not occur until a specified time possibly later in the evening when electrical rates are better To override this feature and begin charging immediately push the button Pressing the button will alternately Stop and Re Start charging The button will not initiate charging unless the cable is connected and the vehicle is requesting a charge There are two Load Management inputs labeled High Low and High Off on a terminal block as shown in Fig 9 below Grounding High Off will completely inhibit charging until it is released Grounding High Low will tell the CS 60 to send a signal to the vehicle instructing it not to charge but instead to draw only a minimum amount of current for auxilliary uses such as cooling down the battery pack or pre heating the cab in the early morning Fig 9 4 Position Terminal Block fe aH Aejoy IH 1O H O a N Load Management Terminal Block Inputs Relay Output The 2 terminals labeled Relay Out 1 amp 2 are dry contacts that are normally open If the Protection light comes on or if other intern
7. CLIPPERGREEK INC INNOVATIVE INFRASTRUCTURE FOR ELECTRIC AND HYBRID VEHICLES m User s Manual ClipperCreek Inc 11850 Kemper Rd Suite E Auburn CA 95603 Model CS 60 CS 60 User s Manual PLEASE NOTE This user s manual includes the latest information at the time of printing ClipperCreek Inc reserves the right to make changes to this product without further notice Changes or modifications to this product by other than an authorized service facility could void the product warranty If you have questions about the use of this product contact your customer service representative Refer to the Customer Support section located in this guide CS 60 User s Manual Version 06 December 2008 CS 60 User Manual DLP 081201 v06 pmd Copyright O 2008 ClipperCreek Inc All rights reserved Printed in the USA Notes CS 60 User s Manual CUSTOMER SUPPORT Call your Service Representative at any time 24 hours a day at the number below PLEASE HAVE THE MODEL NUMBER AND SERIAL NUMBER AVAILABLE WHEN YOU CALL These can be found on the side of the enclosure If your call is made after business hours or on weekends please leave your name telephone number the unit s serial number and a brief description of the problem A Service Representative will call back at the earliest opportunity Distributor Place Contact Information Sticker Here MAINTENANCE The CS 60 requires no periodic maintenance other than occasion
8. al cleaning Warning To reduce the risk of electrical shock or equipment damage do not allow liquid to enter the unit while cleaning it Turn off your charge station at the circuit breaker before cleaning 2 Clean your charge station using a soft cloth lightly moistened with mild detergent solution Never use any type of abrasive pad scouring powder or flammable solvents such as alcohol or benzene Please visit ClipperCreek s Website www clippercreek net Page 19 CS 60 User s Manual CONTENTS IMPORTANT SAFETY INSTRUCTIONS Safety Guidelines se u sawasqa saus ee eee FCC INFORMATION OPERATION Front Panel ossa ek Ria VER SO bane COR UID bese In Case of Difficulty ossos ua 0 0 0 0c ee eee eee FEATURES Personal Protection System Ground Monitor Circuit Auto Reclosure 2 0 0 pasu wi su w eee Off Peak Charging 2 0400 ssa eed a eg Cold Load Pick p lcm Ren External Error Indication Maintenance Current INSTALLATION service Connections us eer ce REN ue els Mounting Procedures WINE 6 oie anasu saa asas sawa RE RE EE os Testing After Installation 0 0 0 0 0005 FOR THE SERVICE TECHNICIAN SPECIFICATIONS 52 EE era PE TE RUP ET EE payaa rS WARRANTY INFORMATION CUSTOMER SUPPORT
9. al problem is sensed by the CS 60 s computer these contacts will close This can be used to power a remote indicator to warn the user that a problem exists giving them the opportunity to correct the problem and help ensure the vehicle will be charged when needed Page 16 CS 60 User s Manual SPECIFICATIONS for CS 60 Line Input Power Service Entrance Voltage amp Wiring Current Frequency Output Power Dimensions Height Width Depth Color Cable Length Weight without Cable Environment Operating Temperature NEMA Rating Timer Connection Error Relay Contacts Agency Approvals 240V AC single phase L1 L2 and Safety Ground 208V AC 3 phase wye connected Any 2 phases and Safety Ground 240V AC 3 phase delta connected With center tap on one leg must use only the two phases on either side of the center tap The two phases must both measure 120V AC to ground Do not use the third leg 208V stinger 60A Circuit Breaker The maximum current for the vehicle is 48A set by the duty cycle of the Pilot waveform 50 60 Hz Variable depending on vehicle Vehicles will be limited to 48A each At 240V this will be 11 5 KW 304 mm 12 in 457 mm 18 in 203 mm 8 in Gray approximately 6 8 m 22 ft 11 kg 24 lbs 40 C 40 F to 50 C 122 F NEMA 4 outdoor use watertight Ground to disable charging leave open to charge 12 volts with 1K source resistance when open
10. circuit 12 ma sink current when grounded Dry contact 24V AC DC max 5A current max closed if error present UL Listed FCC Part 15 Class B Page 15 CS 60 User s Manual Table 1 Front Panel Indicators Green Red CHARGING PROTECTION Status of CS 60 Vehicle not connected or vehicle not requesting charge The ground fault is ripped the ground is missing or service is required Charging was interrupted by the User or disabled by external Timer or unit is in Cold Load Pickup Note in the table above a symbol indicates the LED is off In Case of Difficulty ClipperCreek recognizes that this Charging Station will be heavily relied upon to charge your electric vehicle for daily transportation needs Therefore every effort will be made to restore service should problems arise In the event of a problem charging will stop and the Red PROTECTION light will come on If this happens please try the two simple steps below before calling your Service Representative 1 Remove the cable connector from the vehicle socket The Red PROTEC TION light may go out If it does go out plug the connector back into the socket and see if charging begins normally 2 If the Red PROTECTION light does not go out when the connector is removed be sure the connector is removed from the vehicle socket and switch off power at the circuit breaker feeding power to the CS 60 Wait a few seconds and switch the ci
11. ging Off Peak Charging For this feature you must have an external timer installed purchased separately and also have your local utility install a special Time of Use meter Many utilities plan to give very low rates to those EV owners who charge in the late evening If a timer is installed you do not have to wait until the late evening to plug the CS 60 s connector into the vehicle You may plug in at any time Even though the vehicle may immediately request a charge the timer will cause the CS 60 to delay energizing the cable until the off peak hours when most electric utilities have light demand With this feature the Green CHARGING light will be blinking while the vehicle is waiting for the timer to allow charging If this feature is desired please call your local utility to be sure the Time of Use meter is available in your area before having the timer installed Technical information to help connect the timer to the CS 60 can be found in the section titled Load Management Inputs on page 16 in this manual Cold Load Pickup This feature is built in to the CS 60 but will only be apparent when the utility power fails during charging If the charging connector is still plugged into the vehicle when utility power is restored the Green CHARGING light will blink and the unit will not energize the cable for a random time between 2 and 12 minutes This is to prevent the utility s grid from experiencing a large surge at turn on allowing EV
12. hey are clean and undamaged 3 Reconnect to the vehicle If the fault condition persists a problem may exist on the vehicle 4 Refer to the vehicle owner s manual for instructions on inspecting and cleaning the charge port 5 Plug the EV connector back into the vehicle 6 Ifthe ground fault error is still detected contact your customer Service Representative for assistance Page 13 CS 60 User s Manual Note The vehicle does not need the owners attention after a power outage The CS 60 will automatically resume charging when power is restored External Error Indication Whenever the Red PROTECTION light is lit a relay on the board will provide a contact closure that can be used to remotely indicate that a problem exists A fleet vehicle yard for example could use this feature to light a lamp or ring a bell in the main office letting them know immediately that a vehicle has a charging problem This early warning helps assure that each vehicle will be properly charged and ready for use when needed Maintenance Current If the unit is set up for Off Peak Charging as described above normal charging current cannot be drawn by the vehicle until the Off Peak hours However the CS 60 can be set up to allow a minimum amount of current while waiting for the timer to allow full rate charging This is known as Maintenance Current used for all power needs on the vehicle except charging the main battery pack An example would be preheati
13. ng the cab or keeping the auxiliary battery topped off As in the Off Peak mode above the Green CHARGING light will flash if the vehicle is connected and waiting for the timer to allow charging The contactor will close immediately to supply this small amount of power but the main battery pack will not be allowed to charge The Maintenance Current feature can be selected by connecting the Timer s control wire to the High Low pin on the 4 terminal Terminal Block Connecting to the High Off pin will remove all power from the vehicle until the Off Peak Charging time arrives The correct pin can easily be identified by looking at the wiring diagram for the CS 60 on page 11 The other two pins on the terminal block are the relay contacts for the External Indicator In summary making the best use of the Maintenance Current feature will require the following 1 Installation of a Time Of Use meter by the electric utility 2 Installation of a clock timer to allow the CS 60 to charge only during the Off Peak hours 3 Connecting the timer s control wire to the High Low pin on the Terminal Block Page 6 CS 60 User s Manual INSTALLATION Service Connections phases of a 3 phase feed You may use any two phases of a 3 phase wye connected feed The center point of the 3 phases usually used as Neutral must be grounded somewhere in the system A current carrying Neutral is not needed by the CS 60 Only Line 1 Line 2 and Ground are requi
14. product and the purchase date before any warranty service can be performed Page 18 CS 60 User s Manual LIMITED WARRANTY ELECTRIC VEHICLE SUPPLY EQUIPMENT MODEL CS 60 ClipperCreek Inc 11850 Kemper Road Auburn California 95603 ClipperCreek shall provide the following warranty with respect to the Products to Representative its Sub Representatives and their customers Product 1 year parts 1 year factory labor ClipperCreek Inc warrants this product to be free from defects in material and workmanship The warrantee period shall commence on the date of installation date first use The product installation date must be evidenced and communicated to ClipperCreek by way of the warrantee registration card or its equivalent The warrantee registration card must be filled out com pletely and accurately and returned to ClipperCreek within 30 days after installation and the product installation date shall be within 6 months after the purchase date If a Product installation date is not communicated to ClipperCreek as described above the product purchase date shall serve as the warranty commencement date If this product is defective in materials or workmanship during the warranty period Clippercreek will at its option repair or replace the product Repair parts and or replacement products may be either new or reconditioned at ClipperCreek s discretion This limited warranty does not cover service or parts to repair damage due to
15. rcuit breaker back on again If the Red PROTECTION light does not come back on re connect the cable to the vehicle Charging should begin normally If charging does not begin or if the Red PROTECTION light comes back on call Service Representative The information gained by the above steps will help the Service Representative decide what the problem is and how best to get your CS 60 operational again as quickly as possible Page 4 CS 60 User s Manual FEATURES The following features are supported by the CS 60 Personal Protection System Ground Fault protection with Self Testing and Auto Reclosure see below no manual resetting or testing is necessary Ground Monitoring Circuit Constantly checking for the presence of a Safety Ground connection Auto Reclosure If a problem occurs that interrupts charging the unit will automatically clear all error indications after 5 minutes and attempt to begin charging again If the problem is immediately sensed a second time it will wait another 5 minutes and try again This process will repeat several times at which point power will be removed and no further attempt will be made The Red PROTECTION light on the front panel will be lit This feature helps ensure that your vehicle will be charged and ready for use when needed Temporary problem indications such as ground faults or utility power surges can be overcome automatically without the need for the user to manually re initiate char
16. re the single leg can supply the required power Caution A 3 phase delta connected transformer secondary without a center tap on one leg is not usable with the CS 60 No neutral point is available to be connected to ground for ground fault protection and the CS 60 will not allow the contactor to close if it does not sense the presence of a ground wire connected to a neutral point on the transformer secondary Page 9 CS 60 User s Manual Mounting Procedures 1 Locate the wall mounting position Figure 6 Wall mounting of CS 60 of the EVSE Position the bottom of the charge station 38 inches above the ground The mounting holes are spaced 16 apart to accommodate wall studs f you do not have solid structural framing on those centers you must provide an adequate alternative mounting surface for the EVSE Attach the charge station to the wall studs using 4 4 x 2 1 2 lag screws Use a multi set or equivalent if mounting on a concrete wall Remove the applicable knock out in the charge station push the power leads through the hole then connect the power conduit to the hole After mounting continue the installation using the Wiring Instructions beginning on Page 11 Figure 7 CS 60 Installation Template zm 16 008 um LM ae 14179 Page 10
17. red as shown in Fig 4 1 Caution This is a single phase device Do not connect all 3 Caution The two phases used must each measure 120V to Neutral Earth Ground must be connected to Neutral at only one point usually at the Service Entry Breaker Panel Caution If a 240V 3 phase feed is from a Delta connected secondary the leg used must have a center tap That tap must be Grounded Only the two phases either side of the center tapped leg can be used See Fig 5 below A Caution Warranty is void if this unit is wired improperly Warning Only a qualified electrician should perform the installation The installation must be performed in accordance with all local electrical codes and ordinances Only 3 wires are connected but care must be taken that the service transformer secondary connection is definitely known and the 3 wires from the main circuit breaker panel are connected and labeled correctly Figures 3 4 and 5 below show the most common service transformer secondary wiring formats Notice that L1 L2 amp Gnd are labeled on each diagram Those transformer outputs correspond to the same inputs on the CS 60 Also each of the two 3 phase diagrams shows an L3 output which is not used Do not connect all three phases of a 3 phase secondary to the CS 60 This is a single phase device The Neutral at the service panel must be connected to earth ground somewhere in the system on any of the three connection arrangements G
18. round fault protection is not possible unless the Neutral center tap on the service trans former is connected to an earth ground If no ground is provided by the electrical service a grounding stake must be driven into the ground nearby following local electrical codes The grounding stake must be connected to the ground bar in the main breaker panel and Neutral connected to ground at that point Page 7 CS 60 User s Manual e The CS 60 requires a dedicated 208 240 VAC 50 60 Hz single phase circuit with its own 60A circuit breaker e Do not use a GFCI breaker with the CS 60 The CS 60 contains a Personnel Protection circuit that is the equivalent and specifically designed for use with electric vehicles e Only 3 wires are needed to wire the CS 60 Line 1 Line 2 and Service Ground as shown in Fig 8 Wire the unit from the breaker panel using wire sized according to local electrical codes The circuit breaker should be rated at 60A Derating a 60A breaker 20 for continous duty allows 48A of continuous current e The two phases Line 1 amp Line 2 are terminated on the input side of the contactor itself as shown in Figure 8 The Service Ground is terminated on the Ground Terminal at the bottom of the enclosure e Be careful not to damage the PC Board when removing the power entry knockout attaching the conduit or when wiring the service conductors to the contactor Testing After Installation e Apply utility power and obser
19. s in the area to begin drawing current at random times rather than all at once Page 5 CS 60 User s Manual Ground Missing Lit when the unit has detected a missing Service Ground The CS 60 will not close the contactor until a proper Service Ground has been connected The front panel Red PROTECTION light will be lit and the Diag nostic LED will be flashing at a faster rate Note If a missing ground is discovered power should be turned off before re connecting the ground If ground is reconnected without turning off the power it will be necessary to wait 5 minutes for the CS 60 to clear the Ground Missing error Table 2 below illustrates the information that can be obtained from the 4 LEDs on the PC board Table 2 PC Board Diagnostic LEDs LED LED 2 LED 3 LED 4 Diagnostic Load Mgmt GFCI Ground Status Blink Rate Disable Trip Missing Normal Operation slow Charging slow Charge Disabled lit CCID Trip lit Service Required fast Note a symbol indicates the LED is off Page 14 CS 60 User s Manual FOR THE SERVICE TECHNICIAN There are 4 small LEDs on the PC board to help diagnose problems Diagnostic this is the heartbeat of the system When only this LED is slowly flashing the system has not detected any failures If it is lit but not flashing the board is defective If its not lit either no power is applied or the board is defective To test the system press and hold the
20. this product by other than an authorized service facility could void FCC compliance Page 2 CS 60 User s Manual OPERATION The CS 60 Electric Vehicle Charging Station is a conductive charge station that provides the electric vehicle EV user with a safe and manageable link between the power grid and the electric vehicle Figure 1 The CS 60 Front Panel ELECTRIC VEHICLE CHARGING STATION CHARGING 7 PROTECTION The CS 60 Electric Vehicle Charging Station is very easy to use Just remove the charging connector from its holder and plug it into the vehicle s charge port If there is a mechanical latch that holds the connector firmly while charging be sure the latch has clicked into place Normally the vehicle will immediately request a charge the Green CHARGING light will come on and charging will begin After an average driving day it will require a few hours to recharge completely Charging overnight is the most convenient way to ensure the vehicle s full range will be available for the next day If the vehicle has stopped charging the Green CHARGING light will be out Remove the cable and you re ready to use the vehicle If the charging is still in progress first push the button on the CS 60 s front panel The charging light will start blinking Now you can remove the connector Front Panel The front panel has a GREEN and a RED light to indicate the status of the CS 60 The operational state of the unit can be
21. two Charge Test buttons simultaneously If the contactor closes the CS 60 is operating normally If a vehicle is available connect the charging cable The contactor should close If not the charging cable or vehicle socket may be defective or the vehicle is not requesting a charge If the CS 60 detects an internal failure the Diagnostic LED will blink at a faster rate One of the other LEDs may also be lit and indicate the nature of the problem such as an inoperative Ground Fault circuitry or a missing Service Ground Load Management Disable Lit with a slow blinking Diagnostic LED when either the Cold Load Pickup or External Timer mode are active This is not a failure mode merely a status indicator The front panel green Charge LED will be blinking The CS 60 s cable must be connected to a vehicle for this LED to blink The front panel light will be off when the cable is not connected GFCI Trip Lit when the unit has detected a ground fault When a fault has occurred the contactor will open the front panel Red PROTECTION light will also be lit and the Diagnostic LED will be flashing at a faster rate The system waits 5 minutes after sensing a fault then automatically attempts recovery After several such attempts it will stay in the Protection mode If a ground fault error or an EV connection error has been detected 1 Remove the EV connector from the vehicle 2 Inspect the connector and the vehicle s charge port Be sure t
22. ve that only the Diagnostic LED is flashing on the circuit board If it is not flashing the board may be defective e The Charge Test buttons on the PC board simulate connection to a vehicle Push the two Charge Test buttons at the same time The contactor should close and the large Green CHARGING light should light e If a vehicle is available connect the CS 60 to the vehicle and verify that the contactor closes and the Green CHARGING light comes on Installation is complete Page 12 Note To open the enclosure door remove the two screws on the left hand side using a T15 Torx L Driver Wiring Before connecting wires to the CS 60 please carefully read the section of this manual titled Service Connections on page 7 If you are unsure of the type of power provided at the service panel please consult with your local utility or call your Service Representative for assistance Figure 8 CS 60 Service Wiring Vehicle Side 1L1 3L2 CONTACTOR 271 4T2 Service Side 240VAC LINE 2 240VAC LINE 1 SERVICE GROUND Service Entrance Conductors VEHICLE GROUND TERMINAL o VEHICLE SHIELD TERMINAL CS 60 User s Manual READY CHARGE LC DIAGNOSTICS E LD MGMT DISABLE GFCI TRIP EZ GND MSNG CHARGE TEST ClipperCreek Inc MODEL CS 40 Oct 21 2008 PCB V1 3 BOM V1 3 SCHV1 3
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