AeroVironment TurboDX EVSE-DX User manual
TurboDX
EV CHARGING STATION
INSTALLATION GUIDE
TM
Manufacturer’s Information
© 2018 AeroVironment, Inc. All rights reserved.
AeroVironment, EV Solutions, and the AeroVironment logo are trademarks of AeroVironment, Inc.
Corporate names, trademarks, registered trademarks, service marks, symbols, and logos stated herein are property of their
respective companies.
Specications are subject to change without notice. Images of the Dual voltage charger are representative; production models
may vary. Dual voltage charger may be branded under different names.
No portion of these materials may be duplicated, used or disclosed without prior written permission from AeroVironment, Inc.
Disclaimer: This user guide includes the latest information available at the time of printing. AeroVironment, Inc. reserves the
right to make changes to this user guide and/or product without further notice. Changes or modications to this product not
completed by an authorized service provider could void the product warranty.
Corporate Headquarters
AeroVironment, Inc.
EV Solutions™
800 Royal Oaks, Suite 210
Monrovia, CA 91016
Phone: 888-833-2148
Website: www.evsolutions.com
25793-76 Rev. 03
i
A NOTE ON CUSTOMER SUPPORT
To ensure superior service, please take note of your Serial Number when
contacting Customer Support.
Write down the Serial Number of your charger in the “Owner’s Record” above. The
Serial Number can be found on the side of the charger.
Customer Support
1-888-833-2148
OWNER’S RECORD
model:
TurboDX EV Charging Station
serial number (s/n):
purchase date:
To download the User Manual,
visit www.evsolutions.com/ev-charging-product-resources
ii
SAVE THESE INSTRUCTIONS!
This manual contains important instructions for the TurboDX EV Charging Station
that shall be followed during installation, operation and maintenance of the unit.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION.....................................................................1
Symbol Usage........................................................................................2
About Your TurboDX EV Charging Station.......................................2
Packaging Components ......................................................................4
Installation Preparation........................................................................4
SECTION 2: INSTALLATION STEPS FOR WALL MOUNT................6
STEP 1-12...........................................................................................7-12
SECTION 3: TROUBLESHOOTING........................................................ 13
APPENDIX..................................................................................................... 16
Specications ......................................................................................17
High Voltage Warning.........................................................................18
State of California Proposition 65 Warnings ................................18
FCC Information..................................................................................19
Safety Features ...................................................................................19
Limited Warranty.................................................................................20
SECTION 1
INTRODUCTION
2
WARNING
SYMBOL USAGE
Indicates information about safety practices which, if not
followed, may result in serious injury or death.
......................................................................................................
Indicates information about safety practices which, if not
followed, could result in personal injury or are necessary to
prevent re or equipment overheating.
......................................................................................................
Indicates helpful information for installation or usage, but
does not contain personnel or equipment safety related
information.
ABOUT YOUR TURBODX EV CHARGING STATION
Welcome to your TurboDX EV Charging Station – our easy-to-use, compact
power supply for your electric vehicle’s on-board charger. The charger supplies
and manages AC power to your electric vehicle and is compatible with a variety of
battery electric and plug-in hybrid vehicles.
KEY FEATURES
• Compact design
• Overheating protection
• Network flexibility (select models)
• Quick-read status indicators
• Underwriters Laboratories (UL) listed
• SAE J1772 compliant
• Auto-restart in event of ground fault or power outage
240 VAC Operation: the charger requires either a 240 VAC split phase or a 208
VAC two phase dedicated circuit. It draws a maximum of either 16-amp or 32-
amp continuous current and requires a 20-amp or 40-amp rated circuit breaker.
It is recommended that electrical outlets for use with your charger be
installed by a licensed, qualied electrician. To avoid serious injury or death,
installation must comply with the provisions of the National Electric Code
(NEC) and all local codes. In cases of conflict between local codes and the
NEC, local codes shall take precedence. (Plug-in Model only)
DANGER
NOTE
WARNING
3
WARNING
WARNING
DANGER
WARNING
WARNING
This product must be grounded. If it should malfunction or break down,
grounding provides a path of least resistance for electric current to
reduce the risk of electric shock. The TurboDX will not operate unless the
ground is connected.
Do NOT DROP coupler.
...................................................................................................................................
If the output cable becomes separated from the charger module or the
charge coupler, DO NOT ATTEMPT TO REPAIR THE CABLE YOURSELF.
Contact Customer Support for assistance.
...................................................................................................................................
When using your charger, basic precautions should always be followed,
including the following:
• See warnings on side of charging station. Read warnings before
operating the unit the rst time. Read all instructions in this guide
before using this product.
• Shock hazard – make sure the plug is fully inserted into the wall outlet
so that there are no exposed blade surfaces.
• Children should be supervised when in the vicinity of the charger while
plugged in.
• Do not put ngers into the electric charge coupler.
• Do not use in a commercial garage classied for internal combustion
engine vehicles due to vapors of flammable liquids (gasoline) being
present.
..................................................................................................................
4
PACKAGING CONTENT
Inside the box you’ll nd:
1X- TurboDX EV Charging Station
6X- M5 x 10 mm Electronics Cover Mounting Screws
2X - #10 x 2” Mounting Screws with Sealing Washers
NOTE: If you are missing any of these parts, please call Customer Service 1-888-833-2148.
REQUIRED TOOLS (not included)
The following tools are required for installation:
1. Electronic Stud Finder
2. Measuring Tape
3. Carpenter’s Level
4. Drill
5. T25 Torx Bit
6. Hole Saw (with pilot drill) or Step Drill
7. Slotted Screwdriver
INSTALLATION PREPARATION
1. Before installation, check for proper utility power requirements
and disconnect power. Prepare charger mounting site.
• Turn off circuit breaker at power distribution panel and disconnect switch (if
installed) before installing this charger.
• Check upstream circuit breaker; use table below to determine proper circuit
breaker rating.
• Installation should be completed by a licensed, qualied electrician.
Installation must comply with the provisions of all local electrical codes in
country of installation.
16A 20A
32A 40A
5
DANGER
2. Charger mounting site should be located as close as possible to
the dedicated upstream circuit breaker.
• Area around installation site should be free of debris and clutter.
• Do not install charger near heat source (i.e. furnace, water heater, etc.).
• Keep these instructions for future reference.
• For utility wiring, min. wire gauge size of 10AWG (6mm2) for power and
ground wires.
NOTE: Ensure that the circuit breaker and wire sizes are compliant with local codes. Larger size
(lower AWG) wire may be required in certain regions.
Keep these instructions for future reference.
Risk of shock
Turn off circuit breaker and disconnect switch (if
installed) before installation. Do not restore power to
the outlet until installation is complete. Failure to follow
these instructions could result in shock or electrocution.
Before installation, gather all required parts and tools.
SECTION 2
INSTALLATION STEPS
FOR WALL MOUNT
7
STEP 1
Use stud nder to locate wall stud. Mark the center of the wall stud with a line. For
installation on a concreate wall or masonry skip to Step 2.
STEP 2
Measure and mark a point on the wall. Refer to local building codes for required
distance from floor that the unit shall be installed.
INSTALLATION
HEIGHT
8
STEP 3
Decide location of utility wiring entrance: bottom or rear entry. Use a hole saw
or step drill, to create hole sized for the current level of the charge; follow dimple
and groove features on enclosure for hole location. Diameter of drilled holes will
depend on type and size of conduit ts used.
STEP 4
For pedestal installations, skip to Step 5.
Place charging station onto the wall and align the marked point with the top.
Using a T25 Torx bit, insert one mounting screw, with sealing washer, into the top
mounting hole and screw directly into wall.
Use level to straighten the charging station. Fix charging station to wall by drilling
the second mounting screw with sealing washer, through the bottom mounting
hole. Continue installation on Step 7.
TOP
MOUNTING
HOLE
BOTTOM
MOUNTING
HOLE
9
STEP 5
For installing wallbox onto a pedestal, use the dimensions shown to drill holes
onto face of pedestal.
STEP 6
For rear utility power entry, installation shall use a ½” NPT x 1-1/2” threaded pipe
nipple with three ½” sealing lock nuts and two ½” female grommets, as shown.
Make sure all ttings are properly tightened.
.94
.88
.51
8.90
3.25 .20
THREADED PIPE NIPPLE
1/2” NPT X 1-1/2”
1/2” FEMALE GROMMET
1/2” LOCK NUT
WITH GASKET
10
STEP 7
For bottom utility power entry, install conduit tting and tighten locknut. Use the
proper tting for the corresponding conduit size. Verify that the tting meets the
local code requirements.
STEP 8
Make all utility power and ground wire
hookups to terminal block and grounding lug
inside enclosure (wiring for North America
shown). Torque terminal block screws to 20
lb/in.
NORTH AMERICAN POWER CONFIGURATIONS
Utility Input L1 to GND (V) L2 to GND (V) L1 to L2 (V)
240V Split-Phase 120V 120V 240V
208V 3-Phase 120V 120V 208V
EUROPEAN POWER CONFIGURATIONS
Utility Input L1 to GND (V) L2 to GND (V) L1 to L2 (V)
Phase Ground 230V 230V 0V 230V
CHINA POWER CONFIGURATIONS
Utility Input L1 to GND (V) L2 to GND (V) L1 to L2 (V)
Phase Ground 230V 220V 0V 220V
L1 L1 L2L2/N
GND
VEHICLE
LINE
11
STEP 9
Install and fasten the electronics cover assembly to the enclosure using 6 screws.
Screws shall be torqued to a minimum 15 ft/lbs.
STEP 10
Attach front face to front of electronics cover by inserting latches into mounting
holes. Tighten captive screw on bottom of enclosure to secure cover.
12
STEP 11
Wrap the output cable around the enclosure. Run the charger power-up procedure
to prepare it for use.
STEP 12
POWER-UP PROCEDURE:
1. Turn on the circuit breaker.
2. Verify charging station is powered on.
3. During startup of the TurboDX EV Charging Station, the system goes through
a self-test to ensure correct operation. During this test, light ring will briefly
flash red to conrm the self-test is complete and the unit ready for operation.
BLUE STATUS Indicator light will stay solid indicating that charger is receiving
AC power and is ready to charge.
4. Plug the CHARGE COUPLER into your vehicle’s charging outlet until it clicks.
(No click in IEC coupler.) Once latched, the CHARGE COUPLER will not
disengage unless the release button is pressed manually (SAE or GB/T only).
A latching detent ensures engagement for IEC coupler.
5. Charging will start automatically.
CHAPTER 3
TROUBLESHOOTING
14
NOTE
TROUBLESHOOTING
Please refer to this Troubleshooting Guide for possible solutions to common
errors or difculties with charging your vehicle using your portable charger.
Do not attempt to repair or service the charger yourself.
There are no user serviceable parts inside.
A RED TROUBLE indicator may be triggered by several sources, including the
charger, the utility service, or the vehicle. See troubleshooting tips below.
The RED TROUBLE indicator turns on when the charger detects an error whether
it is connected to your vehicle or not. With the RED TROUBLE Indicator on, the
charger will not deliver power to the vehicle. The error must be corrected before
charging begins or resumes.
Problem Possible Cause Solution
BLUE COUPLER STA-
TUS Indicator does
not illuminate
No power to unit Check circuit breaker.
Charger internal
failure
Contact Customer Service for
assistance.
Vehicle will not
charge
RED TROUBLE
Indicator remains
solid
Charge coupler is
not inserted into the
vehicle
Inspect the charge coupler.
Remove the charge coupler from
the vehicle, then reinsert it into the
vehicle receptacle until it clicks. (No
clicks on IEC)
Vehicle is not in a
state to accept a
charge
Verify vehicle charge timer is set to
permit charging. Refer to the vehicle
owner’s manual for charge timer
instructions.
Communication
error between
charger and
vehicle
Contact Customer Service for
assistance.
15
Problem Possible Cause Solution
RED TROUBLE
Indicator is blinking
rapidly
Utility fault 1. Power cycle charger at breaker
box.
2. If the condition persists, have
a qualied electrician inspect
the wall outlet ground circuit
integrity.
3. Repair as required.
Above temperature
limit Cases:
• Temperature
is too high.
The charger
will restart
charging when
it cools down.
4. Inspect charger module for
overheating (hot to the touch).
a. Carefully unplug vehicle
coupler and allow to cool.
b. If the condition persists,
contact Customer Service for
assistance.
5. Remove power to the Wallbox
at the circuit breaker.
6. Have a qualied electrician
inspect the installation.
a. Repair as required.
RED TROUBLE
Indicator is on solid
when connected to
vehicle
RED TROUBLE
Indicator is off
and BLUE STATUS
Indicator is on when
you unplug from
vehicle
Vehicle problem Contact Customer Service.
RED TROUBLE
Indicator is on solid
NOT connected to
vehicle
Charger internal
failure
Contact Customer Service for as-
sistance.
RED TROUBLE
Indicator and BLUE
STATUS Indicator
are flashing red and
white.
Charger trying to
resolve internal
error
Charger will return to normal opera-
tion within 1 minute. If problem
persists, contact Customer Service
for assistance.
APPENDIX
Table of contents
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