ClipperCreek HCS User manual

ClipperCreek, Inc.
Innovative Infrastructure for
Electric and Hybrid Vehicles
• • • • • • •
Model HCS
User Manual

HCS User Manual
2
To view the latest version of this manual please visit
clippercreek.com/installation-manuals
HCS User Manual, Version 14, January 2019
Copyright © 2018 ClipperCreek, Inc.
All rights reserved. Printed in the USA.
Manual Number: 7004-0014
PLEASE NOTE
This user manual includes the latest information at the time of
printing. ClipperCreek, Inc. reserves the right to make changes to

product by other than an authorized service facility may void the
product warranty.
Contact a Customer Service Representative with any questions about
the use of this product. [phone]
WARNING: This product can expose you
to chemicals, including Carbon Black, which
is known to the State of California to cause
cancer. For more information go to:
www.P65Warnings.ca.gov

HCS User Manual
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CONTENTS
IMPORTANT SAFETY INSTRUCTIONS........................................5
Instructions Pertaining to a Risk of Fire or Electric Shock 5
FCC INFORMATION.............................................................................9
OPERATION...........................................................................................10
The HCS Front Panel 11
INSTALLATION - SERVICE CONNECTIONS............................12
MOUNTING PROCEDURES.............................................................18
HCS EVSE Mounting for Hollow-Wall Construction 19
HCS EVSE Mounting for Solid-Wall Construction 20
WIRING INSTRUCTIONS (Hardwired HCS) ..............................22
RECEPTACLE INSTRUCTIONS (Plug-In HCS).........................24
GROUNDING INSTRUCTIONS.......................................................25
HCS Hardwired EVSE Grounding 25
HCS Plug-In EVSE Grounding 25
USING THE PADLOCK.......................................................................26
MOVING & STORAGE INSTRUCTIONS.....................................27
HCS OPTIONAL CONFIGURATIONS...........................................28
ChargeGuard®Enabled HCS 29
Replacement Keys 31
ChargeGuard EX 32
Share2®Enabled HCS 34
Share2®Wiring Instructions 34
Verify Share2®Function is Working Properly 35
Share2®Operating Instructions 35
COSMOS®Load Management Enabled HCS 38
COSMOS®Wiring Instructions 38
COSMOS®Digital Interface Connection 40
COSMOS®Open Collector Output 41
COSMOS®Digital Interface Compatibility 41
COSMOS®ChargeGuard Ex Enabled HCS 42
COSMOS®ChargeGuard ExActivation Instructions 43
MAINTENANCE ...........................................................................44
MOUNTING THE SAE-J1772TM CONNECTOR HOLSTER.....45
CHARGE CABLE WRAP GUIDELINES...................................47
CUSTOMER SUPPORT................................................................48
SPECIFICATIONS.........................................................................49
WARRANTY INFORMATION (3 Year Standard).....................51
WARRANTY INFORMATION (5 Year Ruggedized).................52

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ILLUSTRATIONS
Figures
1. HCS Front Panel............................................................................................11
2. 220/240V Single Phase .................................................................................15
3. 208V 3-Phase, Wye-Connected.....................................................................15
4. 240V 3-Phase, Delta-Connected, w/Center-Tap on One Leg........................16
5. Mounting the HCS to a Hollow-Wall............................................................19
6. Mounting the HCS to a Solid-Wall ...............................................................21
7. Wiring the HCS in a Junction Box................................................................22
8. Preferred Orientation of the NEMA Receptacles Below
the Plug-in HCS.............................................................................................24
9. Locking the SAE-J1772TM Connector with Padlock Included.......................26
10. Charge Connector Secured with Padlock which Cannot
be Removed from Vehicle without Key........................................................26
11. Padlock Used in Combination with Connector Holster After Charging.......26
12. ChargeGuard®(ON or Enabled Position: Charging is enabled.)...................30
13. ChargeGuard®(OFF or RestrictedAccess Position: The EVSE will
be enabled for as long as the vehicle remains plugged in. The EVSE
will reset when the vehicle connector is unplugged.)...................................31
14. ChargeGuard™ EX.......................................................................................33
15. ChargeGuard™ EX Wiring Instructions.......................................................33
16. Share2®..........................................................................................................35
17. Share2®Connect Vehicle #1..........................................................................36
18. Share2®Connect Vehicle #2..........................................................................36
19. Share2®One of the Vehicles Disconnects or Completes Charging...............37
20. COSMOS®Serial and Digital Interface ........................................................39
21. COSMOS®Power Level Hook-ups...............................................................40
22. COSMOS®ChargeGuard EX Control Wires ................................................42
23. Enable COSMOS®ChargeGuard EX............................................................42
24. Mounting the SAE-J1772TM Connector Holster Using the
Exterior Wood Screws and Washers.............................................................46
25. Drape the Charge Cable LooselyAround the HCS Enclosure......................47
Tables
1. Front Panel LED Information........................................................................11
2. Service Connections for Standard and Ruggedized HCS .............................12
 .............................................................28
4. COSMOS®Wiring Instructions.....................................................................39
5. COSMOS®Digital Interface Connection......................................................40
6. COSMOS®Open Collector Output...............................................................41
7. COSMOS®Digital Interface Compatibility..................................................41
8. COSMOS®ChargeGuard EX Wiring............................................................42

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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 this manual or on labels

This means pay particular attention. Notes contain helpful
suggestions.
Cela signie accorder une attention particulière. Les
remarques contiennent des suggestions utiles.
CAUTION: This symbol means be careful. You are
capable of doing something that might result in damage to
equipment.
ATTENTION: Ce symbole signie être prudent. Vous
êtes capable de faire quelque chose qui pourrait causer des
dommages à l’équipement.
WARNING: This symbol means danger. You are in a
situation that could 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.
AVERTISSEMENT: Ce symbole signie un danger.
Vous êtes dans une situation qui pourrait causer des
blessures corporelles. Avant de travailler sur un équipement
électrique, être conscient des dangers présentés par les
circuits électriques et les pratiques courantes de prévention
des accidents.
Instructions Pertaining to a Risk of Fire or Electric Shock
When using the HCS, basic electrical safety precautions should be
followed:
• Use this EVSE to charge electric vehicles equipped with an
SAE-J1772TM charge port only. Consult the vehicle’s owner
NOTE:

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manual to determine if the vehicle is equipped with the
correct charge port.
• Make certain the EVSE SAE-J1772TM charge cable is
positioned so it will not be stepped on, tripped over, or
otherwise subjected to damage or stress.
• This product contains no user serviceable parts. Consult
the Customer Support section in this manual for service
information. Do not attempt to repair or service the EVSE
yourself.
• Do not operate your EVSE if it or the SAE-J1772TM charge
cable is physically open, cracked, frayed, or otherwise visibly
damaged. Contact a Service Representative for service
immediately. Consult the Customer Support section in this
manual for information on the Service Representative in your
area.
• Not for use in commercial garages where a

portion thereof) used for the repair of internal combustion


 
SAE-J1772TM charge cable.
• Do not allow children to operate this device. Adult
supervision is mandatory when children are in proximity to
an EVSE that is in use.
Instructions se Rapportant à un Risque d’Incendie ou de
Choc Électrique
Lorsque l’utilisation de la HCS, précautions fondamentale de
sécurité électrique doivent être suivies:
• Utilisez cette station de recharge pour charger les véhicules
électriques équipés d’un SAE-J1772TM port de recharge
seulement. Consultez le manuel du propriétaire du véhicule

port de recharge.

HCS User Manual
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• Assurez-vous que le SAE-J1772TM câble de recharge sur la
station de recharge est positionné de telle sorte qu’il ne sera pas
piétiné, accroché plus de, ou autrement endommagé ou de subir
le stress.
• Ce produit ne contient aucune pièce réparable par
l’utilisateur. Consultez la section Support à la Clientèle
dans ce manuel pour obtenir des informations de service.
N’essayez pas de réparer ou d’entretenir la station de
recharge vous-même.
• Ne faites pas fonctionner votre station ou le câble de


votre représentant du service pour service immédiatement.
Consultez la section Support à la clientèle dans ce manuel
pour obtenir des informations sur le représentant du service
dans votre région.
• Ne pas utiliser dans les garages commerciaux où un garage

partie) utilisé pour la réparation de véhicules à combustion
interne dans lequel la zone peut être classée en raison

l’essence.)
• Ne posez pas les doigts à l’intérieur de l’extrémité du
SAE-J1772TM coupleur du câble de recharge.
• Ne pas laisser les enfants utiliser cet appareil. Supervision
d’un adulte est obligatoire lorsque des enfants sont à
proximité d’une station de recharge qui est en cours
d’utilisation.
WARNING: Turn off input power to your EVSE at the
circuit breaker panel before servicing or cleaning the unit.
AVERTISSEMENT: Couper l’alimentation d’entrée à
votre station de recharge sur le panneau de disjoncteur
avant de nettoyer ou de réparer l’appareil.

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VENTILATION: Some electric vehicles require an external
ventilation system to prevent the accumulation of
hazardous or explosive gases when charging indoors.
Consult the vehicle owner’s manual to determine if
your vehicle requires ventilation during indoor charging.
VENTILATION: Certains véhicules électriques
nécessitent un système de ventilation externe pour éviter
l’accumulation de gaz explosifs ou dangereux lors de la
charge à l’intérieur. Consultez le manuel du propriétaire du
véhicule pour déterminer si votre véhicule nécessite une
ventilation quand le recharge en salle.
Vehicles which conform to the SAE-J1772TM standard for
communication can inform the EVSE that they require an
exhaust fan. The HCS is not equipped to control ventilation
fans. Do not charge the vehicle with the HCS if ventilation
is required.
Véhicules qui sont conformes à la norme SAE-J1772TM de
communication peuvent informer la station de recharge
qu’ils nécessitent un ventilateur d’extraction. Le HCS n’est
pas équipé pour contrôler les ventilateurs. Ne chargez pas
le véhicule avec les HCS si la ventilation est nécessaire.
CAUTION: DO NOT CHARGE a vehicle indoors if it
requires ventilation. Contact your Service Representative
for information.
ATTENTION: NE PAS RECHARGER un véhicule à
l’intérieur si il nécessite une ventilation. Contactez votre
représentant de service pour plus d’informations.
Save these instructions for future reference.
Conservez ces instructions pour référence future.
NOTE :
NOTE :

HCS User Manual
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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 the EVSE is suspected, the following steps
should be taken before consulting a ClipperCreek Sales or 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 
by other than an authorized service facility may void
FCC compliance.
ATTENTION:
qui conque autre qu’un centre de service autorisé peut
annuler la conformité FCC.

HCS User Manual
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OPERATION
The HCS EVSE is a compact wall or pedestal-mounted EVSE
that provides the Plug-in Hybrid or Battery Electric Vehicle
(together Plug-In Electric Vehicles, or “PEV”) user with a safe
and manageable link between the power grid and the PEV. Both
hardwired HCS and plug-in HCS versions are available.
The HCS is very easy to use. Simply unwrap the SAE-J1772TM

charge port.
Normally, the vehicle will immediately request a charge using a
special communication line in the cable. Within a few seconds the
green “Charging” light on the face of the HCS will turn on and the
charging cycle 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
on the HCS will turn off. To remove the connector head once a
charge cycle has completed (or to interrupt a charge in progress)
press and hold down the latch release lever on the connector handle
then unplug the connector from the vehicle charge port.

HCS User Manual
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The HCS Front Panel
The front panel on the HCS has four
indicator lights, as shown in Figure 1.
POWER (yellow), indicates that
power is available to the HCS.
CHARGING (green), indicates that
the vehicle is requesting a charge and
AC power is currently applied to the
vehicle.
POWER FAULT (red), indicates
that the HCS is not wired correctly.
The problem can be due to improper
grounding or a missing Earth Ground.
The wiring should be examined by a

CHARGING FAULT (red), indicates
that the HCS is unable to communicate
with the vehicle correctly, or a safety
fault condition has been detected by
the unit.
Figure 1: HCS Front
Panel
Table 1: Front Panel LED Information
No power to EVSE. Check
circuit breaker.
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.
Problem with EV communications.
Disconnect and restart.
EV ground fault trip. Check
vehicle connection.
Internal EVSE fault.
Call for service.
1 off off off off
2 ON off off off
3 ON ON off off
4 ON off ON off
5 ON off off ON
6 ON off off blinking
7 ON off blinking blinking
ON - not
blinking
ON - not
blinking
Amber
Power
LED
Green
Charging
LED
Red
Charging
Fault LED Fault Condition
#Red
Power
Fault LED

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INSTALLATION - SERVICE CONNECTIONS
CAUTION: 
circuit provided with the appropriate maximum branch
circuit overcurrent protection in accordance with the
National Electrical Code, ANSI/NFPA 70 (US) or the
Canadian Electric Code C22.2 NO. 280-13 (Canada).
ATTENTION: Pour réduire le risque d’incendie, de se
connecter uniquement à un circuit fourni avec le approprié
circuit de dérivation protection maximale contre les
surintensités, en conformité avec le Code National électrique
ANSI/NFPA 70 (US) ou Code Canadien de l’électricité
C22.2 NO. 280-13 (Canada).
CAUTION: This is a single-phase device. Do not connect
all three phases of a 3-phase feed! You may use any two
phases of a three phase wye-transformer feed. The
centerpoint of the three phases (usually used as Neutral)
must be grounded somewhere in the system. A Neutral
connection is not required by the HCS. Only Line 1, Line 2,
and Ground are required, as shown in Figure 3.
HCS-15 Hardwired 15A
HCS-20 Hardwired 20A
HCS-20R (Ruggedized) Hardwired 20A
HCS-25 Hardwired 25A
HCS-30 Hardwired 30A
HCS-30R (Ruggedized) Hardwired 30A
HCS-40 Hardwired 40A
HCS-40P NEMA 6-50R 40A/50A
HCS-40P NEMA 14-50R 40A/50A
HCS-40R (Ruggedized) Hardwired 40A/50A
HCS-40R (Ruggedized) NEMA 6-50R 40A/50A
HCS-40R (Ruggedized) NEMA 14-50R 40A/50A
HCS-50 Hardwired 50A
HCS-50P NEMA 6-50R 50A
HCS-50P NEMA 14-50R 50A
HCS-60 Hardwired 60A
HCS-60R (Ruggedized) Hardwired 60A
HCS-80 Hardwired 80A
HCS-80R (Ruggedized) Hardwired 80A
HCS Model Connection/Receptacle Type Circuit Breaker Rating
Table 2: Service Connections for Standard & Ruggedized HCS

HCS User Manual
13
ATTENTION: Il s’agit d’un appareil monophasé.
Ne pas relier tous les trois phases d’une alimentation
triphasée!!! Vous pouvez utiliser les deux phases d’un
triphasé en étoile transformateur alimentation. Le point
central des triphasé (généralement utilisé comme Neutre)
doit être mis à la terre quelque part dans le système. Une
connexion Neutre n’est pas exigée par la HCS. Seulement
ligne 1, ligne 2, et Mise à la Terre sont nécessaires, comme
le montre la Figure 3.
CAUTION: The two phases used must each measure 120V
to Neutral. Earth Ground must be connected to Neutral at
only one point, usually at the service entry breaker panel.
ATTENTION: Les deux phases utilisées doivent mesurer
chaque 120V à Neutre. Mise à la terre doit être connecté au
Neutre en un seul point, généralement à l’entrée panneau de
disjoncteurs de service.
CAUTION: If a 240V 3-phase feed is from a Delta-
connected secondary, the leg used must have a center-tap.
That tap must be Grounded. Only the two phases on either
side of the center-tapped leg can be used. See Figure 4.
ATTENTION: Si une alimentation à triphasé 240V
provient d’un triangle connecté secondaire, la bornes utilisée
doit avoir un centretap. Que la tap doit être Mise à la Terre.
Seuls les deux phases l’une ou l’autre côté du centre tapped
brancher peut être utilisé. Voir la Figure 4 ci-dessous.
CAUTION: Warranty is void if this unit is not wired
properly.
ATTENTION: La garantie est annulée si cette unité n’est
pas correctement câblé

HCS User Manual
14
WARNING
the installation. The installation must be performed in
accordance with all local electrical codes and ordinances.
AVERTISSEMENT:
effectuer l’installation. L’installation doit être effectuée
conformément à tous les codes électriques locaux et des
ordonnances.
Only 3 wires are connected, but care must be taken that the service
transformer secondary connection is  known, and the
3 wires from the main circuit breaker panel are connected and
labeled correctly. Figures 2, 3, and 4show the most common
service transformer secondary wiring formats.
Notice that L1, L2, & Ground are labeled on each diagram. Those
transformer outputs correspond to the same inputs on the HCS.
Also, each of the two 3-phase diagrams shows an L3 output, which
is not used. Do not connect all three phases of a 3-phase secondary
to the HCS. This is a single-phase device.
The Neutral at the service panel must be connected to Earth
Ground somewhere in the system on any of the three connection
arrangements. Ground-fault protection is not possible unless the
Neutral (center-tap on the service transformer) 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.
AVERTISSEMENT: Les codes électriques locaux doivent
toujours être respectées lors de l’installation du piquet de
mise à la terre.

HCS User Manual
15
Figure 3: 208V 3-Phase, Wye-Connected
L3 (NOT USED)
L2
L1
GROUND
NEUTRAL
(NOT USED)
120V208V
120V
The following diagrams illustrate the three service transformer
secondary connections most common in North America.
L1
L2
NEUTRAL
120V
120V
GROUND
(NOT USED)
240V
Figure 2: 220/240V Single Phase

HCS User Manual
16
Figure 4: 240V 3-Phase, Delta-Connected, w/Center-Tap on
One Leg
120V
120V
240V
NEUTRAL
(NOT USED)
L1
L2
GROUND
L3 (DO NOT USE!)
With a wye-connected secondary, any two of the legs can
be used to provide 208V to the HCS. For example, L1 &
L2, or L1 & L3, or L2 & L3. Leave the unused leg open.
Do not connect it to a Neutral bar, or to Ground. Be sure
the center point is grounded to Earth somewhere in the
system.
Avec un transformateur étoile-connecté secondaire, deux
des lignes peut être utilisé pour fournir 208V à la HCS.
Par exemple , L1 & L2, ou L1 & L3, ou L2 & L3. Laissez
la borne inutilisée ouverte. Ne le connectez pas à un bar
Neutre, ou à la Mise à la Terre. Assurez-vous que le point
central est Mis à la Terre quelque part dans le système.
NOTE:

HCS User Manual
17
CAUTION: With the delta connection, one leg must be
center-tapped. Only the two phases on either side of the
center tap can be used. The two phases must both 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.
ATTENTION: Avec la connexion triangle, une borne
doit être centretapped, et seulement les deux phases d’un
côté ou de l’autre du centre tap peut être utilisé. Les deux
phases doivent mesurer 120V à Neutre. Ta troisième ligne
(L3) du delta est 208V, par rapport à la position Neutre,
et il est parfois désigné comme un “stinger”. Ne pas
utiliser ce troisième ligne! Consultez la documentation du
transformateur fabricant pour être sûr du borne unique peut
fournir la puissance requise.
CAUTION: A 3-phase delta-connected transformer
secondary without a center-tap on one leg cannot be
used with the HCS. No “Neutral” point is available
to be connected to ground for ground-fault protection.
The HCS 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.
ATTENTION: Un triphasé triangle-connecté
transformateur secondaire sans centre-tap sur le terminal
ne peut pas être utilisé avec la HCS. Aucun point “Neutre”
est disponible pour être connecté à Mise à la Terre pour
protection de défaut à la terre. Le HCS ne permettra pas le
contacteur de fermer si elle ne détecte pas la présence d’un

du transformateur.

HCS User Manual
18
MOUNTING PROCEDURES
Locate the wall mounting position of the EVSE:
• On the hardwired HCS, the three service conductors are

unit. The HCS must be positioned such that this conduit can
reach a nearby junction box.
• On the plug-in HCS, the NEMA plug head is connected by one
foot of cable (including the plug head) to the bottom side of the
HCS. The plug-in HCS must be positioned such that this plug
can safely be inserted into a wall-mounted NEMA socket.
• Position the bottom of the EVSE at a comfortable height and
at least 18 inches above the ground for indoor installations and
24” off the ground for outdoor installations. Ensure that the
LEDs on the front panel of the EVSE can clearly be seen by
the user of the device.
• The HCS has two vertically aligned mounting holes spaced 17”
apart, one each on the enclosure top and bottom. Use a ruler or
template to mark hole locations on the mounting surface.
WARNING: For safety, always turn off input power to the
EVSE at the circuit breaker panel prior to plugging it in or
wiring it to the service lines. Likewise, turn off the circuit
breaker prior to unplugging it or disconnecting the unit
from the service lines.
AVERTISSEMENT: Pour sécurité, toujours désactiver
le courant d’entrée de la station de recharge au niveau du
disjoncteur du panneau avant de le brancher ou de câblage
à les lignes de service. De même, coupez le disjoncteur
avant de le débrancher ou déconnecter l’unité à partir des
lignes de services.

HCS User Manual
19
HCS EVSE Mounting for Hollow-Wall Construction
• Place the unit such that both mounting holes can take
advantage of solid structural framing inside of the wall or a
strong wall surface such as plywood.
• Size ¼”- 20 lag screws are recommended for mounting the
HCS to a wooden structure. Pre-drill appropriately sized pilot
holes to allow the lag screw to grip the wooden structure while
preventing the wood from cracking or splintering while the
screw is fastened.
• The included plastic angle washers can be oriented to allow
the lag screws to be fastened at an angle while still providing a

• 

plastic angle washer and the head of the lag screw.
• If either mounting hole does not have a solid mounting
structure (such as drywall without a solid backing) it will be
necessary to use proper anchoring hardware such as drywall
toggles or molly bolts.
Figure 5: Mounting the HCS to a Hollow-Wall

HCS User Manual
20
HCS EVSE Mounting for Solid-Wall Construction
• To secure the unit in concrete, pre-drill appropriately sized
holes and use multi-set or wedge anchor hardware at both
mounting points.
• To secure the unit in brick or stone, pre-drill appropriately
sized holes and use sleeve anchors at both mounting points.
• The included plastic angle washers can be oriented to allow
bolts to be fastened either at an angle or perpendicular to
the mounting surface. NOTE there are two different sets of
plastic angle washers included. Select those washers that best
accommodate the mounting hardware “angle of attack” and
orient them accordingly.
•
• NOTE that if the head of the mounting hardware is smaller

washer will need to be placed between the plastic angle washer
and the mounting hardware.
• Machine screw size ¼”-20 hardware is recommended
for mounting the HCS. Screw shafts of at least 2” are

diameter, ensure the screw heads are of a larger diameter. Place
appropriately sized washers between the screw heads and the
