ClipperCreek CS 3-Phase User manual

ClipperCreek, Inc.
Innovative Infrastructure for
Electric and Hybrid Vehicles
• • • • • • •
Model CS 3-Phase
Installation Manual

CS 3-Phase Installation 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 modications to this
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.
CS 3-Phase Installation Manual 20170418.indd
CS 3-Phase Installation Manual 2017418.pdf
Copyright © 2017, ClipperCreek, Inc.
All rights reserved. Printed in the USA.
To download or view the latest version of this manual please
visit https://www.clippercreek.com/3-phase
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

CS 3-Phase Installation Manual
CONTENTS
IMPORTANT SAFETY INSTRUCTIONS
Safety Guidelines...................................................................5
FCC INFORMATION ...............................................................6
OPERATION .............................................................................7
Front Panel.............................................................................7
In Case of Diculty...............................................................8
FEATURES ................................................................................ .9
Personal Protection System....................................................9
Ground Monitoring Circuit....................................................9
Auto-Reclosure ......................................................................9
O-Peak Charging .................................................................9
Cold Load Pickup ................................................................10
External Error Indication .....................................................10
Maintenance Current............................................................10
MOUNTING PROCEDURES.................................................12
INSTALLATION - SERVIC E WIRING . ...............................14
Delta Service Connections ..................................................14
Wye Service Connections....................................................15
Front Door Hidden Latch ....................................................16
Service Connections ............................................................17
Testing After Installation......................................................18
OPTIONAL SERVICE CONNECTIONS ...............................19
Load Management Inputs....................................................19
Relay Output........................................................................19
FOR THE SERVICE TECHNICIAN ......................................20
MAINTENANCE ....................................................................23
CUSTOMER SUPPORT..........................................................24
SPECIFICATIONS FOR CS 3-Phase......................................25
WARRANTY INFORMATION ..............................................27

CS 3-Phase Installation Manual
Page 4
ILLUSTRATIONS
Figures
1. The CS 3-Phase Front Panel...................................................7
2. CS 3-Phase Installation Template ........................................12
3. Wall Mounting of CS 3-Phase..............................................13
4. Delta Service Connections ...................................................14
5. Wye Service Connections.....................................................15
6. Front Door Hidden Latch .....................................................16
7. Service Cable Wiring Diagram for 3-Phase AC Charging...17
8. Four-Position Terminal Block ..............................................19
9. Vehicle Cable Wiring Diagram for 3-Phase AC Charging...22
Tables
1. Front Panel Indicators ............................................................8
2. PC Board Diagnostics LEDs................................................21

CS 3-Phase Installation Manual
Page 5
IMPORTANT SAFETY INSTRUCTIONS
Carefully read these instructions and the charging instructions in
the vehicle owner’s handbook before charging the electric vehicle.
The following symbols may be found in this manual or on labels
axed to the EVSE:
This means pay particular attention. Notes contain
helpful suggestions.
CAUTION: This symbol means be careful. There is
potential of doing something that might result in damage to
the equipment.
WARNING: This symbol means danger. This is a
situation that could cause bodily injury. Before working
on any electrical equipment, be aware of the hazards
involved with electrical circuitry and standard practices for
preventing accidents.
ClipperCreek Electric Vehicle Supply Equipment (EVSE) is
designed with the safety concerns of the end user as an utmost
priority; however, the following safety precautions must be read
and followed:
Safety Guidelines
• Use this EVSE to charge electric vehicles equipped with
a conductive charge port only. See the vehicle’s owner’s
handbook to determine if the vehicle is equipped with a
conductive charge port.
• Make certain the EVSEs supply cable is positioned so it will
not be stepped on, tripped over, or otherwise subjected to
damage or stress.
• There 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 EVSE
yourself.
• Do not operate the EVSE with a visibly damaged supply
cable or EVSE. Refer to the Customer Support section
in this manual for information on contacting a Service
Representative.
NOTE
WARNING: Turn o input power to the EVSE at the
circuit breaker panel before servicing or cleaning the unit.

CS 3-Phase Installation Manual
Page 6
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 aect
operation.
If interference with the EVSE is suspected, we suggest the
following steps be taken before consulting a ClipperCreek Sales
and Service Representative for assistance:
1. Reorient or relocate nearby electrical appliances or
equipment during charging.
2. Turn o nearby electrical appliances or equipment
during charging.
CAUTION: Changes or modications to this product
by other than an authorized service facility may void FCC
compliance.

CS 3-Phase Installation Manual
Page 7
OPERATION
The CS 3-Phase EVSE is a conductive EVSE that provides
the Electric Vehicle (EV) user with a safe and manageable link
between the power grid and the electric vehicle.
Figure 1. The CS 3-Phase Front Panel
Remove the charging connector from its holder and plug it into the
vehicle’s charge port. If there is a mechanical latch that holds the
connector rmly while charging, be sure the latch has “clicked”
into place. Normally, the vehicle will immediately request a
charge, the green CHARGING light will turn on, and charging will
begin. Charging overnight is the most convenient way to ensure the
vehicle’s full range will be available for the next day.
If the vehicle has stopped charging, the green “Charging” light will
turn o. Remove the cable and the vehicle is ready to use. If the
charging is still in progress, rst push the button on the CS 3-Phase
front panel. The charging light will start blinking. Now remove the
connector.
Front Panel
The front panel has one GREEN and one RED light to indicate the
status of the CS 3-Phase. Please refer to Table 1 to check the status
of the EVSE.

CS 3-Phase Installation Manual
Page 8
In Case of Diculty
ClipperCreek recognizes that this EVSE will be heavily relied
upon to charge the electric vehicle for daily transportation needs.
Therefore, every eort will be made to restore service should
problems arise.
In the event of a problem, charging will stop and the Red
PROTECTION light will turn on. If this happens, please try the two
simple steps below before calling a Service Representative.
1. Remove the connector from the vehicle socket. The Red
PROTECTION light may turn o. If it does turn o, plug the
connector back into the vehicle socket, and verify that charging
begins normally.
2. If the Red PROTECTION light does not turn o when the
connector is removed, be sure the connector is removed from
the vehicle socket and switch o power at the circuit breaker
to the CS 3-Phase. Wait a few seconds and switch the circuit
breaker back on. Reconnect the cable to the vehicle. Charging
should begin normally.
If charging does not begin, or if the Red PROTECTION light
turns on, call a Service Representative at 1-877-694-4194. The
information gained by the above steps will help the Service
Representative diagnose the problem and get the CS 3-Phase
operational again as quickly as possible.
Table 1. Front Panel Indicators
Status of CS 3-Phase
OFF OFF
ON OFF
OFF ON
ON ON
OFF

CS 3-Phase Installation Manual
Page 9
FEATURES
The following features are supported by the CS 3-Phase:
Personal Protection System: Ground Fault protection with
Self-Testing and Auto-Reclosure, no manual resetting or testing is
necessary.
Ground Monitoring Circuit: Continuously checks for the
presence of a Safety Ground connection.
Auto-Reclosure: If a problem occurs that interrupts charging, the
unit will automatically clear all error indications after 5 minutes,
and attempt to begin charging again. This feature helps ensure
that the vehicle will be charged and ready for use when needed.
If the problem is immediately sensed a second time, the unit will
wait another 5 minutes and try again. This process will repeat
several times, at which point power will be removed and no further
attempt will be made. The Red PROTECTION light on the front
panel will turn on. Temporary problem indications such as ground-
faults or utility power surges can be overcome automatically
without the need for the user to manually re-initiate charging.
O-Peak Charging: For this feature, an external timer needs
to be installed (purchased separately). The local utility may install
a special Time of Use meter. Many utilities plan to give very low
rates to those EV owners who charge in the late evening. If a timer
is installed, it is unnecessary to wait until the late evening to plug
the CS 3-Phase’s connector into the vehicle. Even though the
vehicle may immediately request a charge, the timer will cause the
CS 3-Phase to delay energizing the cable until the o-peak hours
when most electric utilities have light demand. With this feature,
the Green CHARGING light will blink while the vehicle is waiting
for the timer to allow charging. If this feature is desired, please call
the local utility to be sure the Time of Use meter is available before
having the timer installed. Technical information to help connect
the timer to the CS 3-Phase can be found in the section titled Load
Management Inputs on page 19 in this manual.

CS 3-Phase Installation Manual
Page 10
Cold Load Pickup: This feature is built-in to the CS 3-Phase,
but will only be apparent when the utility power fails during
charging. If the charging connector is still plugged into the vehicle
when utility power is restored, the Green CHARGING light will
blink and the unit will not energize the cable for a random time
between 2 and 12 minutes. This is to prevent the utility’s grid from
experiencing a large surge at turn-on, allowing EV’s in the area to
begin drawing current at random times rather than all at once.
The vehicle does not require the operator’s attention after a
power outage. The CS 3-Phase will automatically resume
charging when power is restored.
External Error Indication: Whenever the Red PROTECTION
light turns on, a relay on the board will provide a contact closure
that can be used to remotely indicate that a problem exists. A
eet vehicle yard, for example, could use this feature to light a
lamp or ring a bell in the main oce, indicating that a vehicle
has a charging problem. This early warning helps assure that each
vehicle will be properly charged and ready for use when needed.
Maintenance Current: If the unit is set up for O-Peak
Charging as described above, normal charging current cannot be
drawn by the vehicle until the O-Peak hours. However, the CS
3-Phase can be set up to allow a minimum amount of current while
waiting for the timer to allow full-rate charging. This is known as
Maintenance Current, used for all power needs on the vehicle
except charging the main battery pack. An example would be
preheating the cab, or keeping the auxiliary battery topped o. As
in the O-Peak mode above, the Green CHARGING light will
ash if the vehicle is connected and waiting for the timer to allow
charging. The contactor will close immediately to supply this small
amount of power, but the main battery pack will not be allowed to
charge.
The Maintenance Current feature can be selected by connecting
the Timer’s control wire to the High/Low Pin on the 4-terminal
Terminal Block.
NOTE

CS 3-Phase Installation Manual
Page 11
Connecting to the High/O Pin will remove all power from the
vehicle until the O-Peak Charging time arrives. The correct Pin
can be identied using the wiring diagram for the CS 3-Phase on
page 17 of this manual. The other two pins on the terminal block are
the relay contacts for the External Indicator.
In summary, making the best use of the Maintenance Current
feature will require the following:
1. Installation of a Time-Of-Use meter by the electric
utility.
2. Installation of a clock/timer to allow the CS 3-Phase to
charge only during O-Peak hours.
3. Connecting the timer’s control wire to the High/Low
Pin on the Terminal Block.

CS 3-Phase Installation Manual
Page 12
Figure 2. CS 3-Phase Installation Template
MOUNTING PROCEDURES
1. Locate the wall mounting position of the EVSE:
• Position the bottom of the EVSE enclosure 38” above the
ground.
• The mounting holes are spaced 16” apart to accommodate
common wall studs.
• If there is no solid structural framing on those centers, provide
an adequate alternative mounting surface for the EVSE.

CS 3-Phase Installation Manual
Page 13
2. Remove the applicable knock-out in the EVSE, push the power
leads through the hole, then connect the power conduit to the
hole.
3. Use a multi-set or equivalent if mounting on a concrete wall.
4. Attach the EVSE to the wall studs using four (4) ¼ x 2½” lag
screws.
5. After mounting, continue the installation using the Service
Wiring Instructions beginning on Page 14.
Figure 3. Wall Mounting of CS 3-Phase

CS 3-Phase Installation Manual
Page 14
Figure 4. Delta Service Connections (Motiv drivetrain vehicles cannot
use a Delta Service Connection)
INSTALLATION - SERVICE WIRING
Delta Service Connections
NOTE: Motiv drivetrain vehicles cannot use a Delta Service
Connection.
This EVSE is congured for use with 3-phase AC power. Either
Delta or Wye service connections can be used in most cases; the
exception is that Motiv drivetrain vehicles will have to use a WYE
supply transformer. Delta-feed service connections to the EVSE
must be made in a specic manner, adhering to the following
requirements:
1. One winding MUST BE CENTER TAPPED. This
center tap must be connected to EARTH GROUND at
some point in the system.
2. LINE 1 and LINE 2 must be drawn from the phases at
each end of the center-tapped winding. This provides
120VAC to EARTH GROUND for both LINE 1 and
LINE 2.
3. LINE 3 is drawn from the 208VAC “Stinger” phase.
See Figure 4.

CS 3-Phase Installation Manual
Page 15
Wye Service Connections
NOTE: Motiv drivetrain vehicles must use a Wye Service
Connection.
Wye transformer service connections require that the NEUTRAL
leg be connected to EARTH GROUND somewhere in the system.
The LINE 1, LINE 2, and LINE 3 phases should all measure
120VAC with respect to EARTH GROUND. See Figure 5.
Figure 5. Wye Service Connections (Motiv drivetrain vehicles must use
a Wye Service Connection)

CS 3-Phase Installation Manual
Page 16
Front Door Hidden Latch
To open the enclosure, perform the following:
1. Unfasten the two (2) machine screws on the left edge of
the enclosure lid.
2. Unlatch the hidden latch located underneath the
enclosure inside of the connector compartment.
Figure 6. Front Door Hidden Latch
NOTE: A T15 or T20 Torx driver is needed to open the door.

CS 3-Phase Installation Manual
Page 17
Figure 7. Service Cable Wiring Diagram for 3-Phase AC
Charging
• The GROUND conductor should connect to the Service
Ground terminal lug located at the bottom left corner of the
chassis.
• The LINE 1 120VAC conductor should connect to the left-
most contactor input terminal labeled “2T1.”
• The LINE 3 120V AC or 208V AC “Stinger” conductor should
connect to the central contactor input terminal labeled “4T2.”
• The LINE 2 120VAC conductor should connect to the right-
most contactor input terminal labeled “6T3.”
• The CS 3-Phase requires a dedicated 208/240V AC 50/60Hz,
three phase circuit, with its own dedicated three phase circuit
breaker.
• Do not use a GFCI breaker with the CS 3-Phase. The CS-3
Phase contains a Personnel Protection circuit that is the
equivalent and specically designed for use with electric
vehicles.
Service Connections
NOTE: Torque specs vary
by conguration and are
specied on the inside of
the CS 3-Phase door.

CS 3-Phase Installation Manual
Page 18
Testing After Installation
• Apply utility power, and observe that only the Diagnostic LED
ashes on the circuit board. If it does not ash, the board may
be defective.
• The Charge Test buttons on the PC board simulate connection
to a vehicle. Push and hold the two Charge Test buttons at the
same time. The contactor should close, and the large Green
CHARGING light should turn on.
• If a vehicle is available, connect the CS 3-Phase to the vehicle
and verify that the contactor closes and the Green CHARGING
light turns on.
INSTALLATION IS COMPLETE.
• Only four wires are needed to wire the CS 3-Phase (Line 1,
Line 2, Line 3, and Service Ground), as shown in Figure 7.
Wire the unit from the breaker panel using wire sized according
to local electrical codes. The circuit breaker should be rated to
the appropriate size for the current draw. Derating a three phase
breaker 20% for continuous duty allows for 80% of continuous
current. For example, derating an 80A three phase breaker 20%
for continuous duty allows 64A of continuous current.
• The three phases (Line 1, Line 2, & Line 3) are terminated on
the input side of the contactor itself, as shown in Figure 7. The
Service Ground is terminated on the Ground Terminal at the
bottom of the inner chassis.
• Be careful not to damage the PC Board when removing the
power-entry knockout, attaching the conduit, or when wiring
the service conductors to the contactor.

CS 3-Phase Installation Manual
Page 19
Load Management Inputs:
If the unit has been congured for O-Peak Charging, the Green
CHARGING light may blink after plugging the cable in, and the
contactor may not close. This means that a timer, or other device,
has been connected to the Load Management input, and charging
will not occur until a specied time, possibly later in the evening
when electrical rates are better. To override this feature and begin
charging immediately, push the Start/Stop button.
Pressing the Start/Stop button will alternately Stop and Re-Start
charging. The button will not initiate charging unless the cable is
connected, and the vehicle requests a charge.
There are two Load Management inputs, labeled High/Low
and High/O, on a terminal block as shown in Figure 8 below.
Grounding High/O will completely inhibit charging until it is
released. Grounding High/Low will tell the CS 3-Phase to send
a signal to the vehicle instructing it not to charge, but instead to
draw only a minimum amount of current for auxiliary uses such as
cooling down the battery pack, or pre-heating the cab in the early
morning.
Figure 8. Four-Position Terminal Block
Relay Output:
The two terminals labeled Relay 1 & 2 are dry contacts that are
normally open. If the Protection light comes on, or if other internal
problem is sensed by the CS 3-Phase’s computer, these contacts
will close. This can be used to power a remote indicator to warn
the user that a problem exists, giving them the opportunity to
correct the problem and help ensure the vehicle will be charged
when needed.
OPTIONAL SERVICE CONNECTIONS

CS 3-Phase Installation Manual
Page 20
FOR THE SERVICE TECHNICIAN
There are four small LEDs on the PC board to help diagnose
problems:
Diagnostic: This is the “heartbeat” of the system. When only this
LED is slowly ashing, the system has not detected any failures.
If it is on but not ashing, the board is defective. If the LED is
not slowly ashing, either no power is applied or the board is
defective.
To test the system, press and hold the two Charge Test buttons
simultaneously. If the contactor closes, the CS 3-Phase is operating
normally. If a vehicle is available, connect the charging cable. The
contactor should close. If not, the charging cable or vehicle socket
may be defective, or the vehicle is not requesting a charge.
If the CS 3-Phase detects an internal failure, the Diagnostic LED
will blink at a faster rate. One of the other LEDs may also turn
on and indicate the nature of the problem, such as an inoperative
Ground Fault circuitry, or a missing Service Ground.
Load Management Disable: Turns on, in conjunction with a
slow-blinking Diagnostic LED, when either the Cold Load Pickup
or External Timer mode are active. This is not a failure mode,
merely a status indicator. The front panel green Charge LED will
blink. The CS 3-Phase’s cable must be connected to a vehicle for
this LED to blink. The front panel light will be o when the cable
is not connected.
GFCI Trip: Turns on when the unit has detected a ground fault.
When a fault has occurred, the contactor will open, the front panel
Red PROTECTION light will also turn on, and the Diagnostic
LED will be ashing at a faster rate. The system waits 5 minutes
after sensing a fault, then automatically attempts recovery. After
several such attempts, it will stay in the Protection mode.