ACS User Manual 111221v06 - consecutive.pmd
Contents
1. 100 mm 4 in 80 mm 3 in 3 kg 7 lbs with SAE J1772 connector and 20 cable 30 C 22 F to 50 C 122 F NEMA 4X watertight NRTL Listed FCC Part 15 Class B Page 10 ACS User s Manual CUSTOMER SUPPORT Call your ClipperCreek Inc 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 This information is printed on the labels on the sides of the device enclosure If your call is made after business hours or on weekends please leave your name telephone number the unit serial number and a brief description of the problem A Service Representative will call back at the earliest opportunity Distributor Service Number Here MAINTENANCE The ACS requires no periodic maintenance other than occasional cleaning Warning To reduce the risk of electrical shock or equipment damage be cautious while cleaning the connectors and case 1 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 Page 11 ACS User s Manual WARRANTY INFORMATION ClipperCreek Inc warrants this product to be free from defects in material manufacture and design for a period of one year after the date of purchase If this prod2. lt lt i 5i 4x45 o xy ret MPa k dan ee b ne 10 CUSTOMER SUPPOR T nirre insedia 11 MAINTENANCE sctritincdeiec eek bine eead aE 11 WARRANTY INFORMATION 4 eee eke kek 12 ACS 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 cause bodily injury Before you work on any electrical equipment be aware of the hazards involved with electrical circuitry and standard practices for preventing accidents 2 Warning This symbol means danger You are in a situation that could Instructions Pertaining to a Risk of Fire or Electric Shock When using the the ACS the following basic electrical safety precautions should be followed e Use this charge station to charge electric vehicles equipped with an SAE J1772 charge port only See the vehicle s owner s handbook to determine if the vehicle is equipped with the correct charge port Make certain the charge station s SAE J1772 charge cable is positioned so it will not be stepped on tripped over or otherwise subjected to damage or stress e There
3. read the section of this manual titled Service Connections on page 5 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 Note The three ACS service conductors use stranded 12AWG 75 C copper wire The insulation of each conductor is color coded for standard 120VAC installation KCC 3 Green Ground Black Linel 120VAC to Ground White Neutral Page 9 ACS User s Manual SPECIFICATIONS Line Input Power Voltage amp Wiring Service Conductors Voltage Range Frequency Current Output Power Dimensions Height Width Depth Weight Environment Operating Temperature Enclosure Rating Agency Approvals 120VAC single phase Line Neutral and Safety Ground L1 Neutral and Ground use 12AWG 75 C copper wire 85VAC to 132VAC 60Hz ACS Model Circuit Breaker Maximum Current ACS 15 15A 10A or 12A ACS 20 20A 15A or 16A ACS 25 25A 20A Note that the maximum current for the vehicle is set by the duty cycle of the Pilot waveform Refer to the ACS serial number label for the specific factory set maximum current rating Variable depending upon the ACS model and vehicle demand At 120VAC the ACS 15 outputs approxi mately 1 2KW 10A or 1 4KW 12A the ACS 20 1 8KW 15A or 1 9KW 16A and the ACS 25 2 4KW 20A Dimensions are for the enclosure only 280 mm 11 in
4. to improper grounding or a missing earth ground The wiring should be examined by a qualified electrician Charging Fault red indicates that the ACS is unable to communicate with the vehicle correctly Table 1 Panel LED Information Green Red Red Charging Power Charging Fault Condition LED Fault LED Fault LED No power to EVSE Check circuit off off Not plugged into the EV or the EV is not ready to charge Charging enabled power is applied to the vehicle Improper grounding or ground is not present off ON not Problem with EV communications blinking Disconnect and restart s EV ground fault trip Check binkng blinking ternal EVSE fault Call for service The ACS will automatically restart after 15 seconds Ta a Bi Page 4 ACS User s Manual INSTALLATION Service Connections Caution To reduce the risk of fire connect only to a circuit provided with the appropriate maximum branch circuit overcurrent protection in accordance with the National Electrical Code ANSI NFPA 70 For a model ACS 15 use a 15A circuit breaker For a model ACS 20 use a 20A circuit breaker For a model ACS 25 use a 25A circuit breaker a 3 phase feed You may use any one phase 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 as well as a Ground connection are required by the ACS as shown in
5. CLIPPERGREEK INC INNOVATIVE INFRASTRUCTURE FOR ELECTRIC AND HYBRID VEHICLES User s Manual Model ACS ACS 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 may 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 Please visit ClipperCreek s Website www clippercreek net ACS User s Manual Version 06 December 2011 ACS User Manual 111222v06 pmd Copyright 2011 ClipperCreek Inc All rights reserved Printed in the USA ACS User s Manual CONTENTS IMPORTANT SAFETY INSTRUCTIONS 1 Instructions Pertaining to a Risk of Fire or Electric Shock 1 SAFETY INFORMATION isse taeda gen ehe RON FP dt ee kek keke 2 FCC INFORMATION 2 aedes nad eee cin a idit 2 OPERATION RTT A 3 FRONT PANED en estas a de nianen k Ka n k ese 4 INSTALLATION a 3 43 4244y ED aid rebe dessen ekek ed 5 Service Connections serieen ake g9 004 n RR e ERE RUE 5 Mounting FOC NAS x xidir voted e ddp key nan r erde h sa yadan nue kedeke 8 Wiring TRS CUEHONS ose cease yeda ya er k ye end a van ined psp dea 9 SPECIFICATIONS
6. Figure 3 Caution This is a single phase device Do not connect all 3 phases of Caution The phase used must 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 3 phase feed is from a Delta connected secondary the leg used must have a center tap That tap must be Grounded Only a phase on either side of the center tapped leg can be used See Figure 4 below A Caution Warranty is void if this unit is wired improperl Warning Only a qualified electrician should perform the installation A 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 2 3 and 4 below show the most common service transformer secondary wiring formats Notice that L1 Neutral amp Ground are labeled on each diagram Those transformer outputs correspond to the same inputs on the ACS Also each of the two 3 phase diagrams shows an L2 and an L3 output which are not used Do not connect more than one phase of a 3 phase secondary to the ACS This is a single phase device Page 5 ACS User s Manual The Neutral at the service panel must be connected to earth ground somewhere in the system on any of the three connec
7. ageable link between the power grid and the PEV Figure 1 The ACS Front Panel Powen cHarcine Brower FAULT Bos FAULT Sh GLIPPERGREEK MUHA THE Electric Vehicle Charging Station ELECTRIC VEHICLE CHARGE STATION 120V The ACS is very easy to use Just unwrap the SAE J1772 charge cable and plug the vehicle connector firmly into the vehicle s charge port Normally the vehicle will immediately request a charge using a special communi cation line in the cable and within a few seconds the green Charging light will turn on and charging will begin After an average driving day the vehicle battery pack will require several hours to recharge completely Charging overnight is the most convenient way to maintain healthy batteries and ensure the vehicle s full range will be available for the next day When the vehicle has stopped charging the green Charging light will turn off Remove the charge cable from the vehicle charge port To interrupt a charge in progress press and hold down the latch release lever on the charge cable handle then remove the charge cable from the vehicle charge port Page 3 ACS User s Manual FRONT PANEL The front panel on the ACS has four indicator lights Power yellow indicates that power is available Charging green indicates that AC power is currently applied to the vehicle Power Fault red indicates that the ACS is not wired correctly The problem can be due
8. 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 if it or the SAE J1772 charge cable is physically open cracked frayed or otherwise visibly damaged 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 Do not place fingers inside of the coupler end of the SAE J1772 charge cable e Do not allow children to operate ths device Adult supervision is mandatory when children are in proximity to a charge station that is in use A Save these instructions for future reference Page 1 ACS User s Manual SAFETY INFORMATION Warning Turn off input power to your charge station at the circuit breaker panel before servicing or cleaning the unit Note 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 follow the SAE J1772 standard for communica tion with the charging station can inform the ACS that they require an exhaust fan The ACS is not equipped to control ventilation fans Do not charge your vehic
9. le with the ACS if ventilation is required by your vehicle 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 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 this product by other than an authorized service facility may void FCC compliance Page2 ACS User s Manual OPERATION The ACS Electric Vehicle Charging Station is a compact wall mounted charging station that provides the Plug in Hybrid or Battery Electric Vehicle together Plug In Electric Vehicles or PEV user with a safe and man
10. nside of the wall or a strong wall surface such as plywood e For any remaining mounting holes which do not have a solid mounting structure such as dry wall without a solid backing it will be necessary to use proper anchoring hardware such as drywall toggles or molly bolts For Solid Wall Construction e To secure the unit in concrete pre drill appropriately sized holes and use multi set or wedge anchor hardware at all four mounting points e To secure the unit in brick or stone pre drill appropriately sized holes and use sleeve anchors at all four mounting points Figure 5 Mounting the ACS to a hollow wall 10 ACS User s Manual Machine screw size 10 hardware is recommended for mounting the ACS Screw shafts of at least 2 are recommended The ACS mounting holes are 3 16 in diameter so ensure that the screw heads do not exceed this size Place appropriately sized washers between the screw heads and the ACS enclosure mounting flanges Wiring Instructions Route the ACS conduit to a nearby service panel or junction box Use the included 1 4 trade size watertight fitting to provide a moisture resistant seal with the service panel or junction box If necessary drill a 1 2 diameter hole to accomodate the liquid tight fitting or use the included 1 4 NPT to 1 2 NPT thread reducer kit Figure 6 Wiring the ACS in a junction box Before connecting the ACS service conduc tors please carefully
11. 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 Inc or an authorized ClipperCreek Inc representa tive 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 Page 12 CLIPPERGREEK INC 11850 KEMPER RD SUITE E AUBURN GA 95603 WWW GLIPPERGREEK NET
12. st 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 sure the single leg can supply the required power center tap on one leg is not usable with the ACS No neutral point is available to be connected to ground for ground fault protection and the ACS 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 Caution A 3 phase delta connected transformer secondary without a Page 7 ACS User s Manual Mounting Procedures Locate the wall mounting position of the EVSE The three ACS service conductors are shielded by a 3 foot flexible conduit The ACS must be positioned such that this conduit can reach a nearby service panel or junction box Position the bottom of the charge station at a comfortable height and at least 18 inches above the ground Ensure that the LEDs on the front panel of the EVSE can clearly be seen by anyone who will be operating the device e The ACS has four mounting holes spaced in a 2 wide by 10 tall rectangular pattern Use a template to mark hole locations on the wall For Hollow Wall Construction Place the unit such that at least two but preferrabley all four mounting holes can take advantage of solid structural framing i
13. tion arrangements Ground 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 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 2 220 240V Single Phase L1 A 120V C x NEUTRAL 120V Y L2 NOT USED GROUND 77 Figure 3 208V 3 Phase Wye Connected L3 NOT USED L1 NEUTRAL L2 NOT USED GROUND Page 6 ACS User s Manual Note With a wye connected secondary any one of the three legs in addition to neutral can be used to provide 120V to the ACS For example L1 amp Neutral L2 amp Neutral or L3 amp Neutral Be sure the center point is grounded to earth somewhere in the system Figure 4 240V 3 Phase Delta Connected with center tap on one leg BL nk A L2 Ne USED Bs NEUTRAL GROUND 77 Caution With the delta connection one leg must be center tapped and A only one of the two phases on either side of the center tap can be used The phase used mu
14. uct is defective in materials manufacture or design during this warranty period ClipperCreek Inc 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 include service to repair damage from improper installation improper connections with peripherals external electrical fault accident disaster misuse abuse or modifications to the product not approved in writing by ClipperCreek Inc 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 warranties of merchantability and fitness for a particular purpose are hereby disclaimed 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 Inc any of its authorized sales and service representatives or its parent company be liable to the customer or any third party for any damages in excess of the purchase price of the product This limitation applies to damages of any kind including any direct or indirect damages lost profits lost saving or other special incidental exemplary
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