Black Box EVSW-240-100-60 User manual

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B L A C K
O
X
MAIN POWER SUPPLY MONITORED
240-208V / 120V, Single Phase - 100A
ALIMENTATION PRINCIPALE
240-208V / 120V, Monophasé - 100A
MAX POWER OF DEVICE CONTROLLED
240-208V, Single Phase - 50A Continuous Resistive Load
240-208V, Single Phase –40 FLA Load
DISPOSITIF DE PUISSANCE MAXIMALE CONTRÔLÉ
240-208V, Monophasé - 50A Charge Résistive Continue
240-208V, Monophasé –40 FLA Charge
Electrical Load
Management
Device
MODEL MODÈLE Manufactured by TEI
EVSW240-100-60 Manufacturé par TEI
EVSW INSTALLATION MANUAL
EVSW MANUEL D’INSTALLATION
Read and save these instructions
Lire et garder ces instructions
Compact to Fit Around Most Electrical Panels
Dimensions: L: 8” x W: 6” x D: 4”
Dimensions: L: 203mm x W: 152mm x D: 101mm

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TABLE OF CONTENTS
About this manual
Safety Information
Specifications
Typical Installation
EVSW Installation
Maintenance
2
3
4
4
5
5
ABOUT THIS MANUAL
Errors and inaccuracies
For any inaccuracy or omission, or to
forward any general comments or
suggestions concerning the quality of this
manual, please send an email to
[e-mail]
All information in this manual is subject to copyright protection and other
intellectual property protection of Traditional Electric Inc. and its licensors.
This installation manual cannot be modified, reproduced, or copied without a
prior written authorisation from Traditional Electric Inc. and its licensors.
Additional information is available upon request. The following logos are
trade names or trademarks of Traditional Electric Inc. in the United States and
in Canada
B L A C K
O
X
All other trade names mentioned in this document are the property of their
respective owners and their use in this manual does not mean a sponsorship
or approval of the product. The use of any trade names shown in this
document is strictly forbidden.
In this document, the terms Black Box, Electrical Load Management Device
and EVSW are equivalent.
Electrical Load
Management
Device

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SAFETY INFORMATION
This document describes important safety instructions which must be followed during installation, maintenance, and application of the device.
Warning
Read all instructions prior to using this product.
Always disconnect the device for electric
vehicles power supply before any work.
Use only this device for electric vehicles by
following the technical specifications
indicated in this installation manual.
Do not install the device for electric vehicles
nearby flammable materials, explosives or
fuels, chemical products and vapors.
Never spray this device with water or any
other liquids.
Stop using this device immediately if
defective, cracked, broken or damaged.
Never try to modify, repair or dismantle the
device. Please contact the manufacturer in
case of any malfunction.
Never insert a sharp object inside the device
at the risk of causing damage to the
components.
Any improper use of the device could result in
serious injuries which may cause death. For a
vertical installation on a wall, refer to the
information on the enclosure for the choice of
mounting position.
Precautions
Any improper use of the device can cause
damages and premature wear of the
components, which voids the warranty.
Never use the device above or below the
temperature range of -22 °F to 113 °F (-30 °C to
45 °C). The electrical devices must be kept free
of frost and water vapor at all times.
The installation of the device must be done in
accordance with the latest electrical code
requirements and with consultation of, and
according to the manufacturer’s specification
and guidelines of both the Electrical Vehicle
and the Charging Station. This device will shut
down and re-energize electricity to both the
Electric Vehicle and its Charging Station
without notice.
Notes
It is recommended to schedule the charging of
the vehicle during hours of low electrical
consumption to minimize interruptions to the
electric charging station.
Always check that the device is adequately
fixed to the wall or ceiling or in a location to
avoid any damages.
It is the installer’s responsibility to make sure
that the electric power source is adequate for
the use of the device.
Do not use any cleaning solvents to clean the
device.
Do not paint the device.
Limited warranty
1–Traditional Electric Inc. warrants
the integrated controls against any defects for
a period of one year from the shipping date.
The warranty is limited to the equipment and
components supplied by Traditional Electric
Inc.
2 –In case of incorrect installation,
inappropriate use or repairs done by
unauthorized personnel other than
representatives of Traditional Electric Inc., the
warranty will be automatically void.
3 - Traditional Electric Inc. undertakes
to repair or replace, at site or at the
manufacturing location, at his option, the
defective material only after an evaluation
made by its representative.
4- Traditional Electric Inc. will not be
held liable for damages or delays and will not
be required to pay transport cost of the
charge controller said to be defective.
5- Traditional Electric Inc. shall not be
liable for any indirect damages or delays
caused by faulty workmanship, materials or
on devices install. The also applies to
installations made without regard for the
manufacturer’s instruction and specification
of devices powered after the EVSW.
6- No indemnity will be paid for
repairs, replacement, or modifications
without a prior written consent supplied by
Traditional Electric Inc.
7–Any control device or accessory
supplied with this device to be installed or
connected remotely from the charge
controller will be guaranteed by the
manufacturer only under the special
conditions mentioned in paragraph 5.
8–The components supplied for
repairs are guaranteed for the remaining of
the warranty on the original product or 90
days. The longest period will prevail.
9–All repairs made at the Traditional
Electric Inc. factory are warrantied for 30 days
from the date of repairs.

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SPECIFICATIONS
This device is a safety device with microcontroller that can protect an
electrical distribution circuit in relation with its main breaker. It will prevent
overloading the electrical distribution circuit by turning off the power to the
charging station for the duration that the power demand exceeds 80% of
the main breaker rating.
Voltage and wiring
240/208V AC single phase: L1,
L2, Neutral, Ground.
Terminals size
up to 6 awg (CU)
Frequency
50 to 60 Hz
Operation temperature
-22°F to 113°F (-30°C to 40°C)
Dimensions*(H x W x D) Total weight*
6" x 8" x 4" 5 lb
203mm x 152mm x 101mm (2.27kg)
*Approximative and can change without notice.
Model Name Convention
Device Name –Voltage –Main Service Size –Breaker Feeding End
Device
EVSW –240 –100 –60
EVSW –240 –60 –40
Trip Percentage (TP)
This device- Charge controller for electric vehicles is factory set to turn off
the charging station if the total consumption of a service exceeds 80%
average over 1 second. For other configurations, please contact the
manufacturer.
Power outage
In the event of a power outage, the device automatically restores the power
supply to the vehicle charging station when power returns and the total
monitored current draw is maintained under the setpoint for the
determined delay period.
Recovery time (RT)
Following a power cut to the electric vehicle supply equipment (EVSE), delay
is initiated to monitor the total consumption of the electrical power system.
Power to the vehicle will then be restored if the total load consumption is
lower than 80% of the main circuit breaker rating during this recovery time.
TYPICAL INSTALLATION DIAGRAM

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EVSW INSTALLATION
STEP 1: CHECK THE PACKAGE CONTENTS EVSW-XXX-XXX-XX
1 x Controller & Enclosure 2 x 100 Amp CT
STEP 2: PREPARATIONS FOR INSTALLATION
1. Disconnect power to all devices being worked on or within an unsafe
distance to the working area.
2. Select the device intended location.
-The recommended place for the EVSW to be installed is
directly above the main panel and with adequate air
circulation.
-NOTE: The EVSW controller must be mounted so that the
nameplate remains visible at all times.
Do not install the EVSW:
-Outdoors
-In a location with a high level of risk or in a hazardous location. - for
example, nearby flammable materials, explosives or fuels, chemical
products and hazardous vapors.
WARNING
Warranty void if any devices are installed incorrectly.
STEP 3: INSTALLATION
1. Remove the two cover screws and enclosure cover.
2. Attach the device to the desired location. (Above main electrical panel).
3. Remove black cover of internal control partition unscrewing two
screws.
4. Install CT’s on the main service wires to be monitored by clipping them
onto each main line paying attention to the arrow that indicates
direction of current flow. CT’s should be separated by a minimum of
100 mm from any exposed live parts. Ensure the clip is secured shut.
Fasten them in place with the zip-ties provided. Review and observe all
local safety procedures when working near live parts.
5. Ensure main power lugs have not come loose with installation of CTs.
6. Install CT wires from this area to EVSW control partition area. (Do not
coil wires near any 120/240V wires as this may cause improper
operation).
7. Insert the two blue CT connectors into the corresponding two blue
receptacles on the control board. Check that they are inserted fully.
8. Re-install cover of control partition inside the enclosure being sure not
to pinch any wires or over torque screws.
9. Install electrical lines from supply breaker for the controlled device to
the marked LINE SIDE of contactor and ground attachment.
10. Install electrical lines from end device to be controlled to LOAD SIDE
of contactor and ground attachment.
11. Install enclosure cover. Check for ground faults and when safe
energize. Note: The contactor will not close until a computational
observation delay of between 0 - 30 minutes below threshold current
values. This is dependent on the setting of the white and blue timer
adjustment screw on the control board. If this observation time is too
long it can be adjusted by turning this screw counter clockwise but
should not be set below 1 minute to avoid contactor chattering.

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STEP 4: TEST FOR OPERATION
Test device for correct operation.
MAINTENANCE
Do not use any cleaning solvents on the devices.
Electrical connection must be inspected, maintained, and re-torqued every
6 months by qualified personnel to maintain safe and proper operation.
Troubleshooting
Contactor does not close when device powered on:
There is an initial delay when powered on while the computer algorithm is
checking the electrical service. The contactor will not close until a
computational observation time of between 0 - 30 minutes below threshold
current values. This is dependent on the setting of the white and blue timer
adjustment screw on the control board. If this observation time is too long
it can be adjusted by turning this screw counter clockwise. You can check
for contactor operation by turning this adjustment all the way counter
clockwise and waiting for the current on both monitored lines to drop
below threshold. The contactor should close as soon as this happens. This
adjustment must not be left in this position but should be set above 1
minute to avoid contactor chattering and premature failure. If this step
shows the device is not working, then check for 240V power at the line side
terminations on the contactor. Next check both wire connectors (stack-ons)
on the terminals plugged into the line side of the contactor are secure and
the same with the single wire connector on the other terminal also on the
load side of the contactor. Then check that the wire connectors on each
side of the contactor coil are secure. If these items all have been checked,
please contact the manufacturer.
Improper operation of contactor:
Check if the CT leads are coiled close to other 120/240V lines and if so move
them away from the area as this can cause improper operation. Check if the
CTs are installed in the correct orientation with the arrow shown inside the
CT eye (window opening) pointing in the direction of current flow. Check if
the CTs are closed securely. Verify that both service wires are consistently
below the operational current specifications for up to 30 minutes
(depending on setting of timer adjustment) with an amp meter. If all these
items are verified and improper operation still exists, please contact
manufacturer.
Contactor chatters on and off:
Verify that the white and blue timer adjustment screw on the control board
is set between ½ way and all the way rotated to the right. If adjustment is
needed insert screwdriver and adjust accordingly. Recycle power to the
device. The farther it is set to the right the more time the computer
algorithm will watch the service before allowing the EV to energize. If this is
done and the contactor is still chattering, de-energize and contact the
manufacturer.
We are always happy to have your feedback and we look forward to
hearing from you. Please email all comments to [e-mail]. You
can also contact us by clicking on the message up button on our website at
www.blackbox-in.com.