Bosch Power Xpress User manual

Power Xpress™ Dual Bollard Charge Station Installation Guide
en Installation Instructions
fr Instructions d’installation

Technical Support
USA: 1-877-805-EVSE (3873)
Copyright © 2016 Bosch Automotive Service Solutions Inc.
All rights reserved.
The information, specifications, and illustrations in this guide are based on the latest information available at the time
of printing. Bosch Automotive Service Solutions Inc. reserves the right to make changes at any time, without notice.

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Table of Contents
1.0 Installation Safety 2
2.0 Installation Contents: Bollard and EVSE 2
2.1 Power Xpress EVSE (EL-50600-300) for Bollard Charge
Station 2
2.2 Bollard and Hardware (EL-50600-500) 2
3.0 Tools Suggested for Installation (Not Provided) 3
4.0 Materials Required for Installation 3
5.0 Applicable Electrical Systems 3
5.1 220/240V Single Phase (North America) 3
5.2 208V 3-Phase Wye Connection (North America)
3
5.3 240V 3-Phase Delta Connection (North America) with
Center Tap on One Leg
4
5.4 230V Above Ground (Europe) / 230V Single Phase
4
6.0 Electrical Requirements for Battery Charging 4
7.0 Amperage and Breaker Parameters 5
8.0 Standard Installation 6
9.0 EVSE Power and Status LED Indications 13
10.0 Troubleshooting 13
10.1 Ground Fault Circuit Interrupt (GFCI) Tripped 14
10.2 Missing Ground 14
11. Limited Warranty 14

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1.0 Installation Safety
SAVE THESE IMPORTANT SAFETY INSTRUC-
TIONS
This guide contains important instructions
that must be followed during the installation
of the electric vehicle supply equipment
(EVSE). All instructions should be carefully
read before installation of the EVSE.
WARNING: Turn OFF the circuit breaker
at the service or distribution panel before
performing any electrical work or repairs.
WARNING: TheEVSEshouldbeinstalled by
a licensed electrician in accordance with
all local electrical codes and ordinances,
and all authorities having jurisdiction.
WARNING: Do not install the EVSE near
flammable, explosive, or combustible
materials. Do not locate or store
flammable, explosive, or combustible
materials near the EVSE.
WARNING: Improper installation of the
EVSE can result in personal injury or
product damage.
WARNING: This EVSE installation guide
is not a substitute for electrical safety
precautions.
WARNING: Use this EVSE within the
specified operating parameters. Failure
to do so may result in injury or death.
WARNING: Locate and install this EVSE in
a location where the charge cable will not
be stepped on, tripped over, or subject to
damage or stress.
WARNING: The EVSE 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 grounding terminal on the
EVSE.
CAUTION: Incorrect installation of the
EVSE can result in damage to the vehicle’s
battery and to the Charge Station itself.
These damages will void the warranty for
the vehicle and the EVSE.
CAUTION: Do not operate the EVSE in
temperatures beyond its operating range of
-40°F to +122°F (-40°C to +50°C).
2.0 Installation Contents:
Bollard and EVSE
(EL-50650-XXXX)
2.1 Power Xpress EVSE (EL-50600-300) for
Bollard Charge Station x2
2.2 Bollard and Hardware (EL-50600-500)

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3.0 Tools Suggested for
Installation (Not Provided)
4.0 Materials Required for
Installation
5.0 Applicable Electrical
Systems
IMPORTANT: The onsite service connection
must be properly identified
before installation of the EVSE.
If you are unsure of the available
service connection, consult
the local utility company or
contact Bosch Electric Vehicle
Solutions at 1-877-805-EVSE
(3873).
NOTE: The L1, L2, and Ground outputs (H, N for Eu-
rope) in the following illustrations correspond to
the inputs on the EVSE.
NOTE: For the (earth) ground connection, always con-
nect the neutral at the service panel to earth
ground. Ground fault protection is not possible
unless the neutral (center tap on the service
transformer) is connected to an earth ground.
5.1 220/240V Single Phase (North
America)
NEUTRAL
(NOT USED)
120V
120V
L2
L1
240V
220/240V Single Phase
WARNING: The EVSE is a single-phase
device. Do not connect all three phases
of a 3-phase feed. Only three wires are
connected, take care that the service
transformer secondary connection is
known, and the three wires from the
main-panel circuit breaker are correctly
connected and labeled.
5.2 208V 3-Phase Wye Connection (North
America)
Any two of the legs can be used to provide 208V to the
EVSE with a Wye-connected secondary. For example, L1
and L2, or L1 and L3, or L2 and L3. Reference the wiring
diagram below.
L3 (NOT USED)
120V
NEUTRAL
(NOT USED)
120V
L1
L2
GND

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208V 3-Phase Wye Connection
NOTE: A current-carrying neutral is not required for the
Charge Station for 208V connections.
WARNING: The EVSE must be installed by
a licensed electrician and in accordance
with all local electrical codes, ordinances,
and all authorities having jurisdiction.
WARNING: Do not install the EVSE near
flammable, explosive, or combustible
materials. Do not locate or store
flammable, explosive, or combustible
materials near the EVSE.
5.3 240V 3-Phase Delta Connection (North
America) with Center Tap on One Leg
One leg must be center-tapped, and only the two phases
on either side of the center tap can be used with the
delta connection.
L3 (N
OT USED)
L1
CENTER TAP
L2
120V
120V
NEUTRAL
(NOT USED)
L1
240V
L2
GND
240V 3-Phase Delta Connection
NOTE: The third line (L3 on the illustration of the delta)
is 208V, with respect to the neutral, and is sometimes
referred to as a “stinger.”
WARNING: Do not use this third line.
NOTE: The two used phases must each measure 120V
to neutral or ground.
NOTE: Consult the utility company or the transformer
manufacturer’s literature to verify that the single
leg can supply the required power.
NOTE: The EVSE will only operate properly if it detects
the presence of a ground wire connected to a
neutral point on the transformer secondary.
WARNING: Do not use a 3-phase delta-
connected transformer secondary without
a center tap on one leg and/or without a
neutral point available for the required
ground connection.
5.4 230V Above Ground (Europe) 230V
Single Phase
LINE (H)
230VAC
NEUTRAL (N)
EARTH
230V Single Phase
WARNING: The EVSE is a single-phase
device. When connecting the line and
neutral wires, take care that the service
transformer secondary connection is
known, and the wires from the main circuit
breaker panel are correctly connected and
labeled. The following service connections
are primarily used in Europe and Australia
(sometimes known as “TT Power Grid”).
Please reference the following diagram.
The line, neutral, and earth outputs on the
illustration correspond to the inputs on
the EVSE.

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WARNING: The line connection must
measure 230V RMS to neutral. Earth must
also be connected to the EVSE.
6.0 Electrical Requirements
for Battery Charging
CAUTION: The AC electrical connection
must have a grounded, dedicated service-
main. No other loads shall be connected to
the same circuit. Use of a non-dedicated
circuit could exceed the current rating of
the circuit breaker and cause it to trip or
open.
WARNING: The EVSE must be installed
by a licensed electrician in accordance
with all national and local electrical
codes, ordinances, requirements and all
authorities having jurisdiction.
The conduit may extend up to 24 in. (61 cm) from
ground level. The wiring should extend 66 in. from the
base mounting of the bollard. A sweep is used to direct
the circuit from the conduit to the electric circuit from
the service panel. The three types of acceptable wire
runs are:
• THWN rigid metal Schedule 40 or 80 conduit,
buried 6 in. (15 cm) below ground level, or per local
electrical code.
• THWN nonmetallic Schedule 40 or 80 conduit,
buried 18 in. (46 cm) below ground level, or per
local electrical code.
• UF burial wire (ground solid), buried 24 in. (61 cm)
below ground level, or per local electrical code.
• Conduit must carry conductors for both charge
stations each on a dedicated circuit breaker..
7.0 Amperage and Breaker
Parameters: Field
Requirements and
Adjustments for EVSE
Installation (Not Required
for 40 Amp Circuit
Installation)
1. Unpack the EVSE.
NOTE: The EVSE has been factory set at 30 amp output
for a 40 amp circuit. Proceed to “Standard Instal-
lation” if installing on a 40 amp circuit. For all
other amperages, complete Steps 2 and 3 for
EVSE adjustment.
2. Remove the domed cap from the current-adjustment

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selector (positioned just above the reset button on
the front of the EVSE).
3. Using a small, flat-blade screwdriver, set the cur-
rent-adjustment selector to the applicable output
current-limiting setting..”
NOTE: Positions 6, 7, 8, 9, 0 are not used (X) and
are non-operational. The EVSE will not
function under these settings.
WARNING: The EVSE setting cannot
exceed ampacity ratings of field service
wires or branch circuit protectors.
WARNING: See “output” specification
label located on the side of the EVSE
for maximum amperage setting, per
limitations of vehicle cable and coupler.
NOTE: The EVSE must be de-rated to match line
service power limitations.
CAUTION: Use 75°C (600V) approved wire,
conductor temperature at 30°C ambient in
wet or dry locations.
8.0 Standard Installation
1. Lay down the bollard box and remove the banding.
2. Lift the top off the box and remove the bollard from
the packaging material.
3. Remove the upper cover from the bollard assembly
by removing the cable-management retaining screws
(E) on the rear of the bollard.
4. Remove plastic bag containing locating set screw
(not shown) from inside bollard.
NOTE: The upper and lower plastic bollard covers
are a matched set and cannot be used
inter-changeably with those from other
bollards.
The standard installation design for the Power Xpress
Bollard is a bolt-down external plate.
The standard diameter of the bollard is approximately 7

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in. The bollard height will vary with the application.
CAUTION: Read all instructions before
installing the EVSE.
WARNING: Main service power must be
off and disconnected before attempting to
install the EVSE.
WARNING: The bollard weighs 20 lb per
foot, and the bottom end is significantly
heavier than the top end. Take proper
precautions and use safe lifting practices
when lifting the bollard.
5. Place the bollard where it is to be installed and drill
holes.
6. Install the 3/4 in. anchor bolts in accordance with
industry standards for the type of mounting being
performed.
NOTE: Adapters may be used to attach junction
box to stand pipe. All adapters and boxes
must be suitable for wet locations.
NOTE: Consult national and local codes for ap-
proved service codes.
7. Adjust charging cable strain relief to the following
locations.
- Top unit - 7 in. from EVSE
- Bottom unit - 24 in. from EVSE

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8. Install cable gland in top of wiring chamber.
9. Remove the top plastic cover.
10. Back out fasteners so that they do not extend into
the inside of the bollard.
11. Cut 2 lengths of service cord approximately 6.5 ft.
and 8.5 ft.
12. Feed cord through the length of the bollard. Excess
should extend approximately 14 in. past bollard
base.
13. Feed the length of the charging cable through the
exit hole in the side of the bollard.
NOTE: Fish tape can be used to pass the service
cord through the bollard and past the
EVSE units.
14. Pass the cord for the top unit past the side of the
EVSE and behind the black face.
15. Slide bottom unit into mounting position. Take
caution not to scrape the front surface of the EVSE
against the bollard. Cables and cords will pass by
the sides of the EVSE.
16. Install cord into top wiring chamber of the bottom
unit.

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17. Pass the charging cable through the exit hole on the
side of the bollard.
18. Feed the cord past the side of the EVSE and slide
into position.
19. Install cord into top wiring chamber of the top unit.
20. Tighten fasteners on the back of the bollard.
21. While tightening the fasteners guide the EVSE’s so
that the bottom cover is resting on the ledge of the
bollard.
NOTE: The fasteners will force the EVSE’s snuggly
against the bollard.

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22. Position the strain relief at the bottom of the side
slot metal mounting bracket in the steel bollard.
Position such that the rubber grommet (D) seats on
the opening of the lower plastic bollard cover. Re-
peat on opposite side.
23. Tighten the inner strain-relief nut (A) inside the
bollard hand tight. Using expandable pliers, tighten
the nut an additional 1/4 turn.
NOTE: Do not overtighten the strain-relief nut.
The grommet may pull through.
24. Install cable hooks on the sides of the bollard.

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25. Use a small flat-blade screwdriver or similar tool to
guide the upper plastic cover into seal.
26. While gently pressing down on the upper plastic
cover, carefully slide the screwdriver around the
bollard to extend the upper lip of the seal over the
upper plastic cover. The upper cover may need to be
tapped gently to fully seat it in the seal.
CAUTION: Use care not to cut or damage
the seal during this procedure.
27. With assistance, move bollard next to the prepared
site.
28. Feed cords into the junction box and secure cable
glands.
29. Wire cords to the supply wires and seal the junction
box with a cover suitable for wet location.
30. With assistance, lift bollard onto mounting bolts.
31. Level, adjust, and tighten mounting nuts according
to anchor manufacturer specification.
32. Loop the cables onto the cable-management holder.
33. Remove the strain-relief assembly from the wiring
chamber.

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34. Trim the wire to a length sufficient to make the
connections to the Charge Station terminal block.
35. Strip back 1 1/4 in. (32 mm) of the wire jacket and
3/8 in. (10 mm) from the ends of the individual
conductors.
36. Remove threaded ground lug.
37. Feed the L1 wire into the L1 terminal slot in the wiring
chamber.
38. Feed the L2 wire into the L2 terminal slot in the wiring
chamber.

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39. Attach safety ground wire through the slot on the
ground terminal. Hand-tighten grounding lug.
NOTE: See inside of wiring chamber cover for
wiring schematic.
40. Tighten terminal screws to 1.2 Nm (10.62 in-lb).
41. Reinstall strain relief.
NOTE: Select appropriate orientation of insert
to achieve proper clamping for wire size
used.
CAUTION: Do not overtighten.
42. Attach the wiring chamber lid with four (4) 3/4 in. (20
mm) square-drive screws.
43. Apply the self-adhesive chamber lid label.
44. Switch the main circuit breaker to the ON position and
verify that the Power LED is illuminated solid green and
the Status LED is illuminated solid amber on the EVSE.
45. Place both halves of the plastic base cover over bollard
base. Secure with plastic push pins

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9.0 Power and Status LED
Indications
Power LED Status LED Condition
(Off) (Off) No service supply
power
Green
solid Amber solid
Charge Station
powered; vehicle
coupler not
connected
Green
solid Green solid Waiting to charge
Green
solid
Green
flashing Vehicle charging
Green
solid
1–2 red
flashesevery
2 seconds
Pilotchargingerror*
Green
solid
Solid red,
then green
flash every 2
seconds
Ground fault
detected*
Green
solid Redflashing Ground monitor
interrupted*
Green
solid Red solid Operation fault*
Green
solid (Off) Operation fault*
*See “Troubleshooting” for suggested solutions.

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- No illumination
- Solid illumination
- Flashing illumination
10.0 Troubleshooting
If there is a charging issue proceed with the following
steps. If the issue persists after three attempts call Bosch
at 1-877-805-EVSE (3873) for assistance.
Problem
Indicated
by LED
Status
Solution
Pilot charg-
ing error
1. Verify supply-side power. The green
POWER LED should be on. If green
POWER LED is off, locate load
center/panel and reset breaker.
2. Press the master clear RESET button
on the front panel of the Charge
Station to attempt a charge-restart.
3. If the red STATUS LED remains
on, disconnect the Charge Station
coupler from the vehicle charge port,
wait 10 seconds, and reconnect the
coupler.
Ground
fault
detected
1. Disconnect main service power at
service panel.
2. Disconnect the Charge Station
coupler from the vehicle.
3. Inspect the Charge Station
connector and the vehicle charge
port verifying both are clean and
undamaged. If vehicle charge port
needs cleaning, follow manufacturer
instructions for cleaning. Clean
Charge Station connector with a dry
or damp cloth if necessary.
4. Restore main service power.
5. Reconnect the coupler to the vehicle
port.
Ground
monitor
interrupted
1. Disconnect main service power at
service panel.
2. Disconnect the Charge Station
coupler from the vehicle.
3. Inspect the Charge Station
connector and the vehicle charge
port verifying both are clean and
undamaged. If vehicle charge port
needs cleaning, follow manufacturer
instructions for cleaning. Clean
Charge Station connector with a dry
or damp cloth if necessary.
4. Restore main service power.
5. Reconnect the coupler to the vehicle
port.

Guide d’installation pour station de charge
Power Xpress™ Dual Bollard
fr Instructions d'installation

Assistance technique
É.-U. : 1 877 805-EVSE poste 3873
Copyright © 2016 Bosch Automotive Service Solutions Inc.
Tous droits réservés.
Les renseignements, spécifications et illustrations dans ce manuel sont basés sur les dernières informations disponibles au
moment de la publication. Bosch Automotive Solutions Service Inc. se réserve le droit d'apporter des modifications à tout moment,
sans préavis.