Installation and Service Manual Level 2 AC Pow-R
Contents
1. Instruction Manual IMOEV00002E Effective April 2012 Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE ELN Powering Business Worldwide Contents Description Page 1 2 d OoN P 10 Important Safety Instructions Please Read 2 Symbols and Definitions 2 About the Pow R Station EV Charging EALS E E E E E Ss Installation 0 0 ee 4 Installing the Electrical Service 6 Instructions for Opening Door Latch 7 Installing to the Premise 8 Termination and Configuration 10 Confirming Installation and First Use 12 Installation Validation for Communications GONNCCUVITY cots ebedaneekadiivwes das 14 SPCCITICATIONS sosa ciaceweccn eda eee eee 17 APPEN ar ea boc eee anh aa ee ok 18 For more information visit www eaton com plugin call 1 855 ETN EVSE 1 855 386 3873 or call your local Eaton sales office Instruction Manual IMOEVOO0O02E Effective April 2012 1 Important Safety Instructions Please Read A WARNING ELECTRICAL THIS EQUIPMENT SHOULD BE INSTALLED ADJUSTED AND SERVICED BY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUC TION AND OPERATION OF THIS TYPE OF EQUIPMENT AND THE HAZARDS INVOLVED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DEATH OR SEVERE INJURY READ THIS MANUAL THOROUGHLY AND MAKE SURE YOU UNDERSTAND THE PROCEDURES BEFORE YOU ATTEM2. to Network Figure 24 Ethernet cable connected to RJ45 cable and PC b Note Local Area Connection may be a different name depend ing on how your Ethernet port is setup or if there are multiple Ethernet ports on the test PC Make sure the next steps are done on the Ethernet port that the modem is connected to on the test PG c Go to Properties in the General tab This will open the Connection Properties window See Figure 25 d Double click on the Internet Protocol TCP IP selection See Figure 25 e Make sure the Obtain an IP address automatically is selected See Figure 25 _ Local Area Connection Properties Ge Internet Protocol TCP IP Properties General Altemate Configuration Connect using Eg Intel R 8257 7LM Gigabit Network Co This connection uses the following items El Client for Microsoft Networks ii File and Printer Sharing for Microsoft Networks oos Packet Scheduler 3 Internet Frotocal TCFIF Install Description You can get IF settings assigned automatically if your network supports thie capability Otherwise You need to ask your network administrator for the appropriate IP settings Obtain an IF address automatically Use the following IP address IP address subnet mask Default gateway Uninstall Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnect
3. Slow Single Blink Steady Slow Single Blink Rarely Occurs Vehicle Nuiscance Trip Continually Occurs Vehicle SAE J1772 Compatibility Concern Max Temporary Faults for One Plug Session T If this occurs 5 vehicle related concerns Medium Blink happened during 1 Plug Session A Plug Session is defined as the moment the user plugs the EV Connector into his her vehicle inlet and then removes it Steady J Assymetric Double Blink Steady GF Test Failure Prior to Engaging Charge Session b n S Steady Contactor Failure Steady The occurance of Vehicle Related Errors have reached a maxium The unit is temporarily disabled so that an investigation can be done Steady Slow Single Blink O Steady Very Fast Blink Unit is locked out and not operable gt t Asymmetric Double Blink Unit is locked out and not operable In all Errors Faults the Power ICON will be ON or y Blinking On a few of the Errors the Charging ICON Lea will BLINK to describe the specific Error Press Manual Reset Pushbutton to Clear Error If AutoReclosure is ENABLED the EVSE will auto clear this error after 15 minutes Starting a new Plug Session will also clear the error A new Plug Session is defined as removing the EV Connector from the Vehicle Inlet and re inserting it into the Vehicle Inlet Press Manual Reset Pushbutton to Clear Error Starting a new Plug Session will also clear the error A new Plug
4. A LOCATION TO MOUNT THE UNIT 1 2010 STANDARDS FOR ACCESSIBLE DESIGN 2 CONSULTATION WITH AN ARCHITECT MAY BE NEEDED IN ORDER TO CONFORM TO ALL GOVERNING STANDARDS FOR LOCATION AND PLACEMENT OF ELECTRIC VEHICLE SUPPLY EQUIPMENT 3 LOCATION OF AN AVAILABLE MOUNTING SUPPORT THE WALL MOUNT UNIT MUST BE ANCHORED INTO A MOUNTING SUPPORT SUCH AS A 2 x 4 STUD OR SOLID CONCRETE WALL USING MOUNT ING HARDWARE THAT IS APPROPRIATE FOR THE SURFACE ON WHICH YOU ARE MOUNTING DO NOT MOUNT THIS UNIT TOA STUCCO DRYWALL WALLBOARD 4 LOCATION OF AN AVAILABLE ELECTRICAL SOURCE POWER WIRES MUST BE RUN THROUGH AN APPROVED CONDUIT OR JACKET FROM THE CIRCUIT PANEL TO THE UNIT 5 LOCATION OF THE VEHICLE S CHARGING INLET WHILE PARKED THE UNIT MUST BE LOCATED SO ITS RESPECTIVE CABLE LENGTH IS RIGHT SIZED TO WHERE THE VEHICLE S INLET IS FOR PLUG IN WITHOUT UNDUE MANEUVERING Note These installation location recommendations are based upon general purpose parking trying to serve the most likely plug in vehicle drivers For specific parking such as at home or in a captive fleet scenario where the User knows where the vehicle s inlet will be locate the Pow R Station appro priately Each plug in electric vehicle manufacturer has a different location for where the charging inlet is located on the vehicle Figure 1 Vehicle Inlet Locations Differ by Manufacturer 4 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow
5. R Station Electric Vehicle Supply Equipment EVSE In North America it is recommended to install Pow R Station EVSE s with a high focus on orientating the station toward the front and driver side of parking spaces Suggestions for different types of park ing layouts are illustrated below Pow R Station EVSE Figure 2 90 Degree Parking Pow R Station EVSE Figure 3 45 Degree Parking Installation and Service Manual Instruction Manual IMOEVO0O002E Level 2 AC Pow R Station Electric Vehicle Effective April 2012 Supply Equipment EVSE Wheel stops are recommended to be installed at a minimum dis tance of four feet from the front of the Pow R Station EVSE to the vehicle side of the wheel stop for general purpose parking This distance takes into effect when larger vehicles like the backing up of a pickup truck with a trailer hitch back into such a space For fleet customer with specific vehicles or for parking restricted to plug in a UE vehicles only the wheel stop installation distance may be different Vehicle Front Pow R Station a ENSE a lee oe Pow R Station EVSE w Protective Bollard Figure 4 Parking Bay Garage Recommended Bollard Installation Note The wall mount style of Pow R Station can come with a much longer Area Reference Only cord so in Parking Bays and Garages length of the cord is less of a problem for maintenance Protecting the Location For outdoor installatio
6. Terminate these wires before applying the electrical service wires If none present skip this step and go to the next section RJ45 CAT5 6 NETWORK CONNECTION COMMON DATA LINE B SHIELD B DATA LINE A oooO O00 54321 4321 O RS 232 DB 9 a J12 J11 a TO a MODBUS RTU CONNECTIONS RELAY O J1 F RELAY PCB GND Figure 18 Control Wiring EATON CORPORATION www eaton com 11 Instruction Manual IMOEVOO002E Installation and Service Manual Effective April 2012 Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE 9 Confirming Installation and First Use Charging Indicator Power Indicator Finished Indicator Service Indicator d HT 3 d Remotely Temporary N Override Button Controlled Fault Reset Button Left Button Indicator Indicator Right Button image 2 Status Indicators Payment Authorization Needed Unit Ready for Charge Session Vehicle Connected EVSE Ready Waiting on Vehicle Vehicle Charging Vehicle Has Ended Charge May begin again at anytime Rate of Charge Contolled Remotely and Rate of Charge Controlled Remotely and Charging Set to INACTIVE Charging ACTIVE Figure 19 Status Indicators Step 5 If the Power ICON is BLINKING Authorization is needed Please consult the Authorization section of this document below If the Power ICON is S
7. eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Definitions AC Alternating Current The type of power available in most build ings and on utility poles The Pow R Station EVSE protects Users and vehicles by allowing AC power to flow through it to the vehicle The vehicle then converts the AC to DC Direct Current to charge the traction battery ALC Available Line Current The Pow R Station EVSE tells the vehicle through the J1772 connector s pilot pin how much current in amperes it is allowed to pull on the circuit This allows the car to not exceed the circuit s maximum current rating EVSE Electric Vehicle Supply Equipment EVSE is a general term used for all of the equipment used to supply electricity to the car such as the Eaton Pow R Station EVSE GFCI Ground Fault Current Interrupter GFCI protects Users from faults involving leakage currents going to ground rather than the proper return path of the circuit J1772 The SAE Recommended Practice for conductive charging of hybrid and electric vehicles This standard spells out the physical dimensions of the J1772 connector and the pilot communication between the plug in vehicle and EVSE Pilot The signal through the J1772 connector This signal tells both the vehicle and the EVSE when both are ready to charge and how much current it is allowed to pull This signal is a SAE standard
8. status ah Address Type Assigned by DHCP IF Address Subnet Mask 132 766 735 100 295 255 255 0 Default Gateway 192 168 13 31 Windows did not detect probleme with this connection IF you cannot connect click Repair Figure 26 Support tab of Local Area Connection Status Step 5 Once an IP address is assigned to the PC open an internet browser and go to a website like gridpoint com If the Ethernet service is open it should allow for any popular website to be accessed Step 6 If you are able to access a website then you have verified that the Ethernet service for the Network Manager Controller is properly functioning For more information about confirming Ethernet con nectivity contact Eaton Tech Support at 1 855 ETN EVSE 386 3873 16 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Cellular Connectivity Step 1 Please safely energize the unit The Ethernet Port LED Lights on the Network Manager Controller should now be lit Step 2 After approximately two minutes verify that the LED indicator lights on the Cellular Modem are lit according to the following pattern e Power Solid e Network Solid e Signal e Solid very strong e Fast Blink strong e Normal Blink good e Slow Blink weak e None no signal Figure 27 Cellular Model LED Indicator Lights Step 3 To verify connectivity call Gri
9. the four outside square holes Step 3 Pre drill mounting holes if mounting into a wood stud or drill appropriate sized holes in a solid wall for use with the type of anchor you will be using Step 4 Attach mounting plate to the wall as shown in Figure 11 If installing on a wood stud use 5 16 or 3 8 x 3 long Lag screws and washers These should be galvanized or stain less steel for weather protection if mounting outdoors If mounting onto a concrete block or brick wall use an appro priate anchor for the type of wall on which you are installing the unit Again these should be appropriate for weather conditions if mounting outside EVSE 10 32 MOUNTING STUDS HOLES MOUNTING LOCATION FOR WOOD STUD SINGLE POLE MOUNTING LOCATIONS FOR CONCRETE WALL CONCRETE BLOCK BRICK OR CHANNEL STRUT e EVSE MOUNTING PLATE MOUNTING LOCATION TO WOOD STUD SINGLE POLE ne ee EVSE 10 32 MOUNTING STUD HOLE Figure 10 Unit and Mounting Plate 8 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE MOUNTING PLATE EVSE 10 32 MOUNTING STUD MOUNTING STUD RECOMMEND 3 00 STANDOFF FROM WALL USING CHANNEL OR Figure 11 Typical Wall Mounting Step 5 After the mounting plate is secure to the wall mount the EVSE unit to the mounting plate using the washers and nuts removed in Step 1 Installation and Service Manual Level 2 AC
10. 1 Cable Connector Assembly 9105363G02 Inlet Housing 43 276 Ribbon Cable for User Interface 9105361601 User Interface Unit 9105360601 Contactor 120V 30A 91C05362G02 Contactor 70A C25FNF37B consult with your local sales office to confirm availability Instruction Manual IMOEVOO002E Effective April 2012 ADA Standards for Accessible Design It is very important to consider all STANDARDS FOR ACCESSIBLE DESIGN for Americans with Disabilities when choosing the location and placement of all Electric Vehicle Supply Equipment The follow ing is a direct excerpt from the 2010 ADA Standards for Accessible Design http www ada gov regs2010 2010ADAStandards 2010ADAs tandards htm c3 The Department of Justice published revised regulations for Titles Il and Ill of the Americans with Disabilities Act of 1990 ADA in the Federal Register on September 15 2010 These regulations adopted revised enforceable accessibility standards called the 2010 ADA Standards for Accessible Design 2010 Standards or Standards The 2010 Standards set minimum requirements both scoping and technical for newly designed and constructed or altered State and local government facilities public accommodations and commercial facilities to be readily accessible to and usable by individuals with disabilities Adoption of the 2010 Standards also establishes a revised reference point for Title Il entities that choose to make structural changes to
11. 231 2 Personnel Protection DIP switch selectable Enable Disable default Enabled Randomized Restart On Power Failure Yes delay before charging resumes after a power failure Automatic Reset after Nuisance Trip Feature 10 000 cycles EV Connector replaceable 100 000 cycles Contactor replaceable Mechanical Operations Incoming Field Electrical Service 22 1 26 6 2 5 3 Terminal Block Torque in in lb Nm Incoming Modbus Connections 4 4 5 3 5 6 Terminal Block Torque in in Ib Nm Instruction Manual IMOEVOO0O02E Effective April 2012 Table 6 Physical and Environmental Specifications Description Wall mount Pedestal Dimensions H x W x D 22x10 XG 52 50 x 15 x 8 Add 9 below for cable hanger 6 LEDs Power Charging Complete Remotely Controlled Temporary Fault and Service Status Indicators Push Buttons 2 Buttons Override and Reset Ingress Protection IP14 Type Rating 3R Temperature Operating 30 to 50 degrees Celsius Temperature Storage 40 to 70 degrees Celsius Humidity 90 RH non condensing Table 7 I O Specifications Description Wall mount Pedestal J1772 Pistol Grip EV Same as Output Rating Connector Permissive Run Contact NC dry contact input Available Line Current 4 20mA analog input Control RS 485 Modbus RTU 4 wire port Memory SD Memory Slot Ethernet RJ45 IEEE 802 3 TCP IP
12. ALLED PROPERLY TO MAINTAIN THE PROPER NEMA 3R RAT ING ON THE UNIT A IMPORTANT CONFIRM WITH THE LOCAL ELECTRICAL REQUIREMENTS FOR THE GAUGE TEMPERATURE RATING AND TYPE OF WIRE MATERIAL USED FOR THE OVERCURRENT RATING FOUND BELOW THE CHART SHOWS A GENERAL RECOMMENDATION Table 2 Electrical Wire Chart Style Nameplate Overcurrent Suggested Suggested Suggested Rating Wire Gauge Wire Type Wire Temp Rating Wall mount SAR_B 30A 40A 8 AWG Copper 75 degrees C SAR_C 70A 90A 4 AWG Copper 75 degrees C Pedestal SBR_B 30A 40A 8 AWG Copper 75 degrees C SBR C 70A 90A 4 AWG Copper 75 degrees C Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE 6 Instructions for Opening Door Latch Step 1 Facing the charging station locate the door latch on the right side of the unit as shown in Figure 7 Figure 7 Door Latch Step 2 Insert key into lock and turn counterclockwise note for new instal lations the key will come already in the lock Once unlocked the latch should pop outwards as shown in Figure 8 s oe paame tes E has LP Figure 8 Unlocked Door Latch Instruction Manual IMOEV00002E Effective April 2012 Step 3 Rotate the handle counterclockwise to release latch as shown in Figure 9 The door should pop open Figure 9 Rotate Handle to Release Latch EATON CORPORATION www eaton com 7
13. Copper Conductors Only Grounding Instructions This product must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment ground ing terminal Optional Level 1 120VAC Outlet When the EVSE is equipped with a Level 1 120VAC Outlet perform the wiring instructions outlined below in Figure 16 Level 1 Field Connection Diagram GFCI Receptacle Screw terminal colors Green grounding terminal Silver white terminals Brass hot terminals LINE oe a ee Hot terminal Brass LINE ii P Connection for the White tarminal Silver i j LINE cable s black Connection for the LINE im f wire cable s white wire g S BACK VIEW Grounding Terminal Green Connection for bare A yellow sticker covers the LOAD terminals Do not LOAD White terminal Silwer Connection for the LOAD cable s white wire Hat terminal Brass Connection for the LOAD cable s black Wire Figure 16 Optional Level 1 120VAC Outlet INCOMING ELECTRICAL SERVICE TERMINATIONS TORQUE in lbs Nm 22 1 26 6 2 5 3 Use Copper Conductor Only COUPLE po Ibf Nm 22 1 26 6 2 5 3 Conducteurs de cuivre seulement Figure 17 GFCI Receptacle Location Reference Only Control Wires RJ45 CAT5 6 network cable or a 4 wire shielded Belden cable for Modbus communication may be needed based upon the configura tion of your Pow R Station
14. EVSE If the vehicle wants to engage a charging again at a later time while you are away it may do so at anytime No additional activity is required by you At anytime you may remove the EV Connector and Re Dock it to the EVSE If the vehicle wants to engage charging again at a later time while you are away it may do so at anytime No additional activity is required by you Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Table 11 EVSE Fault or Error User Interface Indicators EVSE Fault or Error User Interface Indicators Instruction Manual IMOEVO0002E Effective April 2012 Will present itself in a blink pattern or a steady icon Typically is a vehicle related concern Eaton defines this as a Temporary Fault or in rare occurances a Nuiscance Trip Will present itself in a y blink pattern or a steady icon Typically an internal EVSE Concern T SAE J1772 Concern Steady Fast Double Blink Rarely Occurs Vehicle Nuiscance Trip Continually Occurs Vehicle SAE J1772 Compatibility Concern Q SAE J1772 Concern Fast Double Blink i ld Steady Slow Single Blink Rarely Occurs Vehicle Nuiscance Trip Continually Occurs Vehicle SAE J1772 Compatibility Concern id Ground Fault Concern Ig Steady Slow Single Blink Steady Rarely Occurs Vehicle Nuiscance Trip Vehicle Tried to Pull more Power the the EVSE has instructed it to pull O
15. Instruction Manual IMOEVOO0O02E Effective April 2012 7 Installing to the Premise The three typical installation methods of installing Pow R Station EVSE s to the premise are found below Some installations require installing the wall mount style of Pow R Station EVSE to a wall or unistrut Mounting to a Wall Preparing the Site Once a proper site has been chosen and the electrical service has been run to the location you can begin installation A CAUTION DO NOT MOUNT UNIT TO ONLY STUCCO DRYWALL WALLBOARD DO NOT USE TOGGLE BOLTS ZIP ANCHORS NOR PLASTIC WALL ANCHORS MEANT FOR THESE MATERIALS BECAUSE THEY DO NOT HAVE THE STRENGTH NEEDED TO SUPPORT THE UNIT THE UNIT MUST BE MOUNTED TOA SOLID SUPPORT SUCH AS WOOD CONCRETE WALL CONCRETE BLOCK WALL OR EQUIVALENT Step 1 Remove the mounting plate from the back of the EVSE unit by placing the unit on a solid non scratch surface and opening the unit by turning the latch on the side Remove the three nuts on the 10 32 studs that attach the mounting plate to the unit The location of these mounting studs can be seen in Figure 10 Save these nuts and washers as they will be needed to re attach the unit later in the installation Step 2 Using the mounting plate as a template mark the holes to be used for mounting Make sure the mounting plate is level If mounting on a wood stud wall use the two center holes If mounting on a solid wall such as concrete brick or concrete block use
16. Modbus TCP Field Diagnostics and RS 232 DBS HyperlerminalTM Support Upgrade Port Table 8 Optional Specifications Description Wall mount Pedestal Through feed Daisy Chain No Yes Compatible Enables connectivity to Pow R Station Network Manager with real time status and historical information Network controller Wireless Wi Fi WPA or WPA2 RFID basic Basic lock unlock with card or keyfob RFID User Customer provided third party database of users inte grated for authentication Cellular GPRS GSM Credit Card Processing PCI DSS Pow R Station Network Management Solution with Real time Status and Historical Information Network Management Table 9 Optional Level 1 120VAC 20A Outlet 120VAC 60 Hz Same as incoming Incoming Voltage Input Frequency Output Voltage Output Frequency Same as incoming Output Amperage Max Continuous 20A EATON CORPORATION www eaton com 17 Instruction Manual IMOEVOO0O02E Effective April 2012 Appendix Table 10 EVSE Normal Operation User Interface Indicators Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE EVSE Normal Operation User Interface Indicators Unit is Ready for Use Authorization is required Steady Vehicle Connected EVSE Ready Waiting on Vehicle Steady Vehicle Connected and Vehicle Charging Vehicle Connected and Charging is Remotely Controlled by Building Manageme
17. PT TO OPERATE THIS EQUIPMENT THE PURPOSE OF THIS MANUAL IS TO PROVIDE YOU WITH INFORMATION NECESSARY TO SAFELY OPERATE MAINTAIN AND TROUBLESHOOT THIS EQUIPMENT KEEP THIS MANUAL FOR FUTURE REFERENCE DO NOT USE THIS PRODUCT IF THE EV CABLE IS FRAYED HAS DAMAGED INSULATION OR ANY OTHER SIGN OF DAMAGE DO NOT USE THIS PRODUCT IF THE ENCLOSURE OR THE EV CONNECTOR IS BROKEN CRACKED OPEN OR SHOW ANY OTHER INDICATION OF DAM AGE INTENDED FOR USE WITH PLUG IN ELECTRIC VEHICLES ONLY PREMISE VENTILATION NOT REQUIRED THE INFORMATION CONTAINED IN THIS MANUAL IS SUBJECT TO CHANGE WITHOUT NOTICE 2 Symbols and Definitions A WARNING ELECTRICAL THIS SYMBOL INDICATES HIGH VOLTAGE IT CALLS YOUR ATTENTION TO ITEMS OR OPERATIONS THAT COULD BE DANGEROUS TO YOU AND OTHER PERSONS OPERATING THIS EQUIPMENT READ THE MESSAGE AND FOL LOW THE INSTRUCTIONS CAREFULLY A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED CAN RESULT IN SERIOUS INJURY OR DEATH A CAUTION INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH IF NOT AVOID ED CAN RESULT IN MINOR TO MODERATE INJURY OR SERIOUS DAMAGE TO THE EQUIPMENT THE SITUATION DESCRIBED IN THE CAUTION MAY IF NOT AVOIDED LEAD TO SERIOUS RESULTS IMPORTANT SAFETY MEA SURES ARE DESCRIBED IN CAUTION AS WELL AS WARNING A IMPORTANT INDICATES A PARTICULAR ITEM OR INSTRUCTION THIS IS IMPORTANT TO CONSIDER Save These Instructions 2 EATON CORPORATION www
18. Plug Session The time while the EVSE is plugged into a vehicle It starts by plugging in the J1772 connector and ends when unplug ging the same connector SAE Society of Automotive Engineers The group that organizes and leads committees of transportation experts to create standards such as J1772 for the transportation industry Traction Battery The large battery on a plug in electric vehicle that is used to store and release energy for propulsion This is different than the 12V battery that is used to start the vehicle initially and run accessories such as the radio UI The User Interface part of the unit TB The Terminal Block is where the incoming field power will be terminated in the EVSE unit ADA Americans with Disabilities ACT Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE 3 About the Pow R Station EV Charging Station Eaton s Pow R Station is Electric Vehicle Supply Equipment EVSE and is compatible with the Society of Automotive Engineers J1772 standard for charging plug in hybrid and all electric vehicles The Pow R Station EV Charging Station has several safety features e Protects Users with interlocked power the cable and pins have no power on them until the connector is safely plugged into a vehicle e Protects Users from temporary faults and automatically resets so no User interaction is needed e Instructs the vehicle
19. Pow R Station Electric Vehicle Supply Equipment EVSE Mounting to Uni Strut Once a proper site has been chosen and the electrical service has been run to the location you can begin installation Step 1 Step 2 Remove the mounting plate from the back of the EVSE unit by placing the unit on a solid non scratch surface and open ing the unit by turning the latch on the side for details see Section 6 Instructions for Opening Door Latch Remove the three nuts on the 10 32 studs that attach the mounting plate to the unit The location of these mounting studs can be seen in Figure 10 Save these nuts and washers as they will be needed to re attach the unit later in the installation Using the mounting plate as a template determine where the anchors should be placed to be used for mounting It SINGLE STRUT POLE an MOUNT Figure 12 Typical Unistrut Mounting D CENTER MOUNTING HOLES Figure 13 Dimensional Detail for Unistrut Mounting MOUNTING LOCATIONS Step 3 Instruction Manual IMOEV00002E Effective April 2012 is recommended in high wind and use area cross arms should be used to avoid twisting which can occur in a single pole installation Make sure the mounting plate is level If mounting on a single pole use the two center holes If mounting utilizing cross arms use the four outside square holes Attach mounting plate using as shown in Figure 12 Use appropriate hardware making sure it is g
20. SA Publication No IMOEV00002E TBG000585 April 2012 Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Eaton is a registered trademark of Eaton Corporation All other trademarks are property of their respective owners
21. Session is defined as removing the EV Connector from the Vehicle Inlet and re inserting it into the Vehicle Inlet Press Manual Reset Pushbutton to Clear Error Starting a new Plug Session will also clear the error A new Plug Session is defined as removing the EV Connector from the Vehicle Inlet and re inserting it into the Vehicle Inlet Press Manual Reset Pushbutton to Clear Error Starting a new Plug Session will also clear the error A new Plug Session is defined as removing the EV Connector from the Vehicle Inlet and re inserting it into the Vehicle Inlet Starting a new Plug Session will clear the error A new Plug Session is defined as removing the EV Connector from the Vehicle Inlet and re inserting it into the Vehicle Inlet Call Technical Support 1 855 ETN EVSE Ensure that the Incoming Electrical Wires are Landed according to the Installation Manual the EVSE Requires an L1 L2 and Ground Please consult the Installation Guide for further details Call Technical Support 1 855 ETN EVSE Call Technical Support 1 855 ETN EVSE Call Technical Support 1 855 ETN EVSE EATON CORPORATION www eaton com 19 Instruction Manual IMOEVOO0O02E Effective April 2012 ETN Powering Business Worldwide Eaton Corporation Electrical Sector 1111 Superior Ave Cleveland OH 44114 United States 877 ETN CARE 877 386 2273 Eaton com 2012 Eaton Corporation All Rights Reserved Printed in U
22. TEADY please proceed to the Step 1 Ensure that the electrical service wires are landed accord ing to this manual Make sure the station access door is closed next step Step 2 Power ON the Distribution Breaker j ou oe Step 6 If a SAE J1772 Compliant Electric Vehicle is available please Step 3 During initial EVSE boot up the User Interface will cycle all connect the EV Connector to the Vehicle Inlet You may also ICONS use an Eaton Vehicle Simulator Step 4 After boot up the Power ICON will be either STEADY or Step 7 The CHARGING INDICATOR will begin to blink BLINKING per above table If this is not the case please verify that all incoming service connections are landed appropriately and that the distribution breaker is in tact If the Power ICON still does not appear please call technical support Step 8 Almost immediately the vehicle will engage a charge ses sion the contactor will close and power will be supplied to the vehicle See Table 10 Normal Operation User Interface Indicators in the Appendix for more details 12 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Step 9 When power is being supplied to the vehicle the CHARGING INDICATOR will move from a BLINK status to STEADY status signifying that current is flowing to the vehicle Step 10 You may now remove the connector from the vehicle at your leisure Auth
23. To enable or disable this feature a Service Technician must change the position of a dip switch on the control board Instruction Manual IMOEVOO002E Effective April 2012 e To Enable Automatic Reset Dip Switch Block SW 2 Position 6 must be ON e To Disable Automatic Reset Dip Switch Block SW 2 Position 6 must be OFF For board replacements or basic confirmation of settings Table 3 contains the explanation of the dip switch settings found in the corner of the Eaton Protection and Control Board EPCB near the RS232 Serial port labeled SW1 and SW2 Table 3 Dip Switch Settings Dip Dip Feature ON OFF Description Switch Switch Block Position SW2 1 Voltage US 120V US Voltage Configuration 208 240V Configuration of the Unit For 120V Configuration A Wire Jumper needs to be added between L2 and N on Figure 15 of this Document SW2 2 Operating 60Hz 50Hz North America is Frequency 60Hz SW2 3 4 Reserved for Reserved for Factory Use and 5 Factory Use SW2 Auto reset Enabled Disabled Comes from the after fault factory disabled A vehicle fault must be reset manu ally the owner can easily enable this feature via this dip switch Doing so will enable an auto reclosure on a nuisance trip SW2 7 Soft Start Default in OFF Position If ON the EVSE will perform a ramp up of current to the Available Line Current ALC or Nameplate Rating over a 30 second time period This is done through the SAE J1772 han
24. alvanized or stain less steel for weather protection if mounting outdoors Step 4 After the mounting plate is securely attached to the mount ing structure mount the EVSE unit to the mounting plate using the washers and nuts removed in Step 1 POLE MOUNT WW CROSS BRACES MOUNTING LOCATIONS MOUNTING LOCATIONS UNISTRUT WITH CROSS BRACES UNISTRUT WITH CROSS BRACES Vas EATON CORPORATION www eaton com 9 Instruction Manual IMOEVOO0O02E Effective April 2012 Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE FRONT of Pedestal Station 1 00 REF eT 1 00 REF Figure 14 Base Detail Pedestal for EVSE Pedestal Floor Mounting Preparing the Site Once a proper site has been chosen and the electrical service has been run to the location you can begin installation Step 1 Open door using the latch on the side of the unit see Section 6 Instructions for Opening Door Latch for details Step 2 Remove the bottom pan by pulling upward and then angling outward Best if performed when door is held opened Step 3 The hole pattern for the base of the pedestal mount is shown below in Figure 14 Use six 3 8 UNC Grade 5 stain less bolts torqued at 50 ft lbs for mounting base to the ground Note If using a concrete pad please be mindful of the overall height of the unit due to ADA Compliance Please reference the ADA Compliance secti
25. ation EVSE For a typi cal installation the only field wires will be for the incoming electrical service If the EVSE has a Level 1 option additional service and wiring will be needed If the EVSE unit has a remote management option a standard CAT5 6 network cable or 3 wire shielded cable typical for a RS485 type network could also need to be run to the unit The Pow R Station operates on a single phase service two hots and one ground Note Use Copper Conductors ONLY A IMPORTANT THE 30A LEVEL 2 EVSE REQUIRES A DEDICATED 208 240VAC 40A UPSTREAM BREAKER THE 70A LEVEL 2 EVSE REQUIRES A DEDICATED 208 240VAC 90A UPSTREAM BREAKER OPTIONAL LEVEL 1 OUTLET REQUIRES DEDICATED 120VAC 20A UPSTREAM BREAKER DO NOT USE GFCI BREAKERS GFCI EXISTS IN EVSE AND ON LEVEL 1 OUTLET For detail on termination of Level 1 option see page 10 6 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE A WARNING ELECTRICAL WARNING LOCKOUT TAGOUT ALL ELECTRICAL SOURCE CIRCUITS FEEDING THE UNIT S IN THE OPEN POSITION BEFORE BEGINNING WIRING OR TERMINATIONS FAILURE TO FOLLOW THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH A WARNING THIS UNIT IS RATED FOR INDOOR OR OUTDOOR INSTALLATION IF THIS UNIT IS MOUNTED OUTDOORS THE HARDWARE FOR CONNECTING THE CONDUITS TO THE UNIT MUST BE RATED FOR OUTDOOR INSTALLATION AND BE INST
26. ctions the local area network must have access to the following two web addresses e Address 1 endpoint gridpoint com e Address 2 ems gridpoint com Please confirm access to these sites with the facility s IT depart ment Ethernet Connectivity If the EVSE is setup to connect via hardwired Ethernet over Cat5 6e cable Step 1 Verify the network providing the Ethernet service to the EVSE has DHCP enabled or if there are any firewalls on the Ethernet drop Ask facility s IT if you are not sure Ensure firewalls will not prevent the Network Manager Controller from connecting to gridpoint com Step 2 Disconnect the Ethernet Cable from the Network Manager Controller See Figure 23 3 Figure 23 Disconnecting Ethernet cable from Network Manager Controller Instruction Manual IMOEVOO002E Effective April 2012 Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE Step 3 Use an RJ45 coupler to connect the Ethernet cable that was just dis connected from the Network Manager Controller to an RJ45 cable and PC as shown in Figure 24 a On test PC running Windows XP navigate to Start gt Control Panel gt Network Connections and double click on the Local Area Connection icon This will open the connection status window for that Ethernet connection Step 4 Setup your PC to obtain an IP address automatically RJ45 Rj 45 Cable RJ 45 Cable Coupler
27. dPoint technical support at 1 866 800 and provide them with the Network Manager controller serial num ber For more information about setting up connectivity to Network Manager see the Network Manager quick start guide document LOEVOOOOGE Wi Fi Connectivity Please refer to Instructional Leaflet ILOEVOOOO8E Level 2 AC Pow R Station electric vehicle supply equipment Wi Fi configuration quick start guide to confirm Wi Fi connectivity Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE 11 Specifications The Eaton Pow R Station EVSE is compliant with the following stan dards e Society of Automotive Engineers SAE J1772 2010 EV Conductive Charge Coupler and Station e NFPA 70 National Electric Code Article 625 Electric Vehicle Charging System e UL 2231 Personnel Protection Systems for EV Charging Circuits e UL 2594 EV Supply Equipment Outline of Investigation e UL 1998 Software in Programmable Components e FCC compliant Part 15 Table 5 Electrical and Mechanical Specifications Description 30A 70A Incoming Voltage 208 VAC 208 240 VAC 240 VAC 120 VAC Input Frequency 50 60Hz 50 60Hz Incoming Amperage 40 A 90 A Output Voltage Same as Incoming Output Frequency Same as Incoming Output Amperage Max Continuous 30A 70A Interlocked Power Output Yes Yes Overcurrent Rating Output Amperage 5 Ground Fault Interruption 20mA UL2231 1 UL2
28. dshake with the vehicle by modifying the Duty Cycle on the Pilot Signal SW2 8 Reserved for Default in OFF position Factory SW1 1 Reserved for Default in OFF position Factory SW1 2 and 3 RS485 Baud See Baud Rate Dip Switch Table Default is Rate all ON SW1 A55 7 R5485 Range 0x00 to 0x1F using binary addressing and 8 Address Most Significant Bit being SW1 Position 4 Default is all OFF except Position 8 i e 0x01 Table 4 RS485 Baud Rate Dip Switch Table Baud Rate SW1 Position2 SW1 Position 3 9600 OFF OFF 19200 OFF ON 38400 ON OFF 115200 ON ON EATON CORPORATION www eaton com 13 Instruction Manual IMOEVOO0O02E Effective April 2012 CI Oo Oo OI Z O m o0 o0 o O 0l ON Figure 22 Dip Switch Settings for a 208 240V 60Hz 30A Pow R Station with Auto reset DISABLED 14 EATON CORPORATION www eaton com Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE 10 Installation Validation for Communica tions Connectivity Communications to Network Manager There are several communication options to enable connectivity to Network Manager available for Pow R Station EVSE The following instructions detail the validation procedures for confirming connectiv ity for cellular Wi Fi and Ethernet communication options Please note that in order for the unit to connect to Network Manager via Wi Fi and Ethernet conne
29. ed networks Obtain ONS server address automatically O Use the following DNS server addresses SS Preferred DMS server s TAT Slternate ONS server Show icon in notification area when connected temate DNS server Notify me when this connection has limited or no connectivity I eee i Local Area Connection Status General Connection Statue Duration Speed Activity Fackets Figure 25 PC setup dled Connected 09 45 47 100 0 Mbps Recetved 56 306 GRelacs U5 SecurelD Disconnected LSI HDA Modem Eaton Internet Intl Disconnected RL LSI HDA Modem GRelacs UK SecurelD Disconnected RL LSI HDA Modem 1394 Connection Connected Wireless Nekwork Connection Nok connected Le A ma 2 I 2 Eaton Internet Disconnected LSI HOA Modem GRelacs UK SecurelD Disconnected LSI HDA Modem Eaton Internet Intl Disconnected LSI HOA Modem Local Area Connection Connected Ty Intel R 82577LM Giga EATON CORPORATION www eaton com 15 Instruction Manual IMOEVOO0O02E Effective April 2012 f Hit Ok for the two windows to close them g In the Local Area Connection Status go to the support tab and verify that an IP address has been assigned Jot down the Default Gateway address for the Wifi Troubleshooting portion Note It does not need to match exact numbers in Figure 26 l Local Area Connection Status General Suppor Connection
30. existing facilities to meet their program accessibility requirements and it establishes a similar reference for Title Ill entities undertaking readily achievable barrier removal The Department has assembled this online version of the official 2010 Standards to increase its ease of use This version includes 2010 Standards for State and Local Government Facilities Title Il and 2010 Standards for Public Accommodations and Commercial Facilities Title Ill The Department has assembled into a separate publication the revised regulation guidance that applies to the Standards The Department included guidance in its revised ADA regulations pub lished on September 15 2010 This guidance provides detailed information about the Department s adoption of the 2010 Standards including changes to the Standards the reasoning behind those changes and responses to public comments received on these topics The document Guidance on the 2010 ADA Standards for Accessible Design can be downloaded from htto Awww ada gov For information about the ADA including the revised 2010 ADA regu lations please visit the Department s website www ADA gov or for answers to specific questions call the toll free ADA Information Line at 800 514 0301 Voice or 800 514 0383 TTY EATON CORPORATION www eaton com 3 Instruction Manual IMOEVOO0O02E Effective April 2012 4 Installation Choosing a Location A IMPORTANT THINGS TO CONSIDER BEFORE CHOOSING
31. ns creative use of protective bollards and Figure 6 Protecting the Pow R Station EVSE with Bollards for wheel stops are necessary Vehicles can and will damage the units Reference Only if left unprotected Protective bollards are recommended to be installed in the area in close proximity of the Pow R Station EVSE See local jurisdiction requirements for actual specifications Pow R Station EVSE Cb cd R Wheel Stop Figure 5 Protecting the Pow R Station EVSE with Wheel Stops for General Purpose Parking EATON CORPORATION www eaton com 5 Instruction Manual IMOEVOO0O02E Effective April 2012 5 Installing the Electrical Service Checking the Electrical Requirements The National Electric Code Article 625 21 states Overcurrent protection for feeders and branch circuits supplying electric vehicle supply equipment shall be sized for continuous duty and shall have a rating of not less than 125 percent of the maximum load of the electric vehicle supply equipment A load study of the location s electrical service may be needed to determine the availability of adequate electrical service Take the nameplate amperage rating of the Pow R Station and multiply by 125 for the minimum upstream circuit protection needed Check your local jurisdictions for any other electrical requirements Running the Wires Once the proper electrical overcurrent device has been installed wire needs to be run from it to the Pow R St
32. nt System Charging Set to INACTIVE Steady in Vehicle Connected and Charging is Remotely Controlled by Building Management System Charging Set to ACTIVE but at a reduced level Vehicle Connected and Current Charge Session is Complete Vehicle Connected and Current Charge Session is Complete 18 EATON CORPORATION www eaton com Remove EV Connector from EVSE and Mate to your Electric Vehicle Plug In to Vehicle to Begin Charge Session A If the EVSE has a RFID reader please present your keyfob or other credential to activate B Otherwise proceed to process payment via Credit Card Payment System on the front of the unit After payment is rendered EVSE will activate and Power ICON None Waiting on Vehicle to Begin Charging If vehicle does not begin charging momentarily please check internal scheduling system or remove and re insert EV Connector Wait for Full Charge or Disconnect When you are Ready to Leave You can now walk away from the unit Charging will begin with Building Management System Allows Depending on Facility Setup Local Override may be available by pushing the Override Pushbutton You can now walk away from the unit Charging will begin when Vehicle Engages Charge Session Depending on Facility Setup Local Override may be available by pushing the Override Pushbutton This will request to charge at full capacity At anytime you may remove the EV Connector and Re Dock it to the
33. on of this document 10 EATON CORPORATION www eaton com 5 15 8 Termination and Configuration WARNING ELECTRICAL WARNING LOCKOUT TAGOUT ALL ELECTRICAL SOURCE CIRCUITS FEEDING THE UNIT S IN THE OPEN POSITION BEFORE BEGINNING WIRING OR TERMINATIONS FAILURE TO FOLLOW THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH WARNING ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE OPERATION AND CONSTRUCTION OF THIS EQUIPMENT SHOULD INSTALL ADJUST MODIFY AND SERVICE THIS EQUIPMENT FAILURE TO FOLLOW THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH Wire Terminations For a typical installation the only field wire terminations will be the incoming electrical service wires If the EVSE unit is configured for Pow R Station Network Manager or other remote management solu tion a standard CAT5 6 network cable or 3 wire shielded cable for RS 485 Communications Electrical Service Wires Terminate the incoming electrical service wires to the Pow R Station EVSE s provided terminal block following the designations for each wire L1 L2 and G see Figure 15 Installation and Service Manual Level 2 AC Pow R Station Electric Vehicle Supply Equipment EVSE GROUND Instruction Manual IMOEVOO002E Effective April 2012 LINE 2 INPUT LINE 1 INPUT HOT HOT Figure 15 Electrical Service Wiring Note Torque for incoming field service wiring 22 1 26 6 in lb 2 5 3 0 Nm Use
34. on how much current to draw keeps the upstream circuit protection from nuisance tripping e Allows integration into authorization and management systems keeping only authorized personnel able to use units and power usage levels to predefined levels e See section Specifications for more details Automatic Reset feature must be enabled during installation see page 15 for more information Moving Transporting and Storage Instructions Store this unit indoors and in its original packaging until it is ready to be installed Storage temperature should be between 30 and 80 C When moving or lifting the unit always grasp the unit enclo sure NEVER attempt to lift move or carry the unit by the EV cable DO NOT carry the unit by the cable hook assembly Improper storage or handling may cause damage to the unit Before You Begin A WARNING ELECTRICAL WARNING ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE OPERATION AND CONSTRUCTION OF THIS EQUIPMENT SHOULD INSTALL ADJUST MODIFY AND SERVICE THIS EQUIPMENT FAILURE TO FOLLOW THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH A IMPORTANT THE USER IS RESPONSIBLE FOR CONFORMING TO ALL LOCAL AND NATIONAL ELECTRIC CODE STANDARDS APPLICABLE IN THE ENVIRON MENT THAT THE POW R STATION IS BEING INSTALLED AND COMMIS SIONED Replacement Parts List Table 1 Replacement Parts List Part Part Number Protection and Control Board PCBA 910537060
35. orization Needed If Authorization is needed the Power ICON will have a BLINK pat tern This signifies to the end User that either payment activation is needed or RFID authorization Ground Fault Test Figure 20 Ground Fault Test The ground fault detection feature is self tested every time the unit starts a plug session to charge a vehicle A User can manually test the ground fault feature at any time by pressing and holding the reset button right button for seven seconds If the test passed suc cessfully the fault light will flash once If it detects a problem the power icon will turn off and the service light wrench icon will have a medium single blink until power is cycled to the unit See Table 11 EVSE Fault or Error User Interface Indicators in the Troubleshooting Section in the Appendix for more details Dip Switch Settings A CAUTION MODIFYING THE DIP SWITCH CONFIGURATION OF THE UNIT COULD CAUSE THE UNIT NOT TO OPERATE AS DESIRED PLEASE ONLY MODIFY DIP SWITCH SETTINGS IF YOU ABSOLUTELY UNDERSTAND THE IMPACT TO THE UNIT Automatic Reset Feature From the manufacturer the Pow R Station is set to require a manual reset after a temporary fault The User has to opt in to enable the automatic reset feature Figure 21 Enabling Disabling Automatic Reset During installation the Automatic Reset setting can be either left dis abled as it came from the factory or the User can decide to enable the feature
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