PowerCharge Energy Series User manual

POWERCHARGE™ Energy series
80 amp ev charging station
P C EVower HARGE .COM
USER MANUAL

| Energy Series | 80A | EV Charging Station User Manual
2
Safety Instructions..................................................................................................
Repair & Maintenance Clause.............................................................................
General Care.............................................................................................................
Customer Support..................................................................................................
FCC Interference Statement...............................................................................
Industry Canada......................................................................................................
Radiation Exposure Statement..........................................................................
Safety Warnings & Symbols................................................................................
3
3
3
3
4
4
4
5
6
6
7
8
8
9
9
Product View.............................................................................................................
Box Contents.............................................................................................................
Product Specications...........................................................................................
Pre-installation steps..............................................................................................
Grounding instructions..........................................................................................
Unboxing the charging station...........................................................................
Tools and parts required for installation.........................................................
Important Safety Instructions.....................................
Introduction.....................................................................
Technical Specications...............................................
Pre-Installation................................................................
Installation Steps............................................................
Input Power Cord Installation......................................
Holster Installation......................................................
Operations........................................................................
Charging Your Electric Vehicle...................................
3-5
6
7
8-9
10-11
12-13
14
15
15
TABLE OF CONTENTS

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This document contains instructions and warnings that must be followed when
installing and using the Electric Vehicle Supply Equipment (EVSE).
Before installing or using the EVSE, read this entire document as well as WARNING and
CAUTION markings in this document.
The information provided in this manual in no way exempts the user of responsibility to
follow all applicable codes or safety standards.
This document provides instructions for the Electric Vehicle Supply Equipment (EVSE)
and should not be used for any other product.
Only licensed electricians can repair or maintain this equipment. It is forbidden for
general users to repair or maintain it.
Turn off input power before repair or maintenance on this equipment.
The exterior of the charge point is designed to be waterproof and dust proof. To ensure
proper maintenance of the charging station, follow these guidelines:
• Despite the water resistance of the enclosure, when cleaning it is preferred to not
direct streams of water at the unit. Clean with a soft, damp cloth.
• Make sure the charging plug is put back in the holster after charging to avoid
damage.
• Ensure the power cable is stored on the charge point after use to avoid damage.
• If the power cable or the charging plug is damaged, please contact Customer
Support.
Contact PowerCharge™ for technical support.
PowerChargeEV.com | [phone]
The symbols used have the following meaning:
WARNING
Risk of personal injury WARNING
Risk of electrical shock
WARNING
Risk of re or explosion
CAUTION
Risk of damage to the equipment
IMPORTANT SAFETY INSTRUCTIONS
Safety Instructions
Repair and Maintenance Clause
General Care
Customer Support

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Federal Communication Commission Interference Statement
Radiation Exposure Statement:
Déclaration d’exposition aux radiations:
Industry Canada statement:
This equipment complies with part 15 of the FCC rules. Operation is subject to the
following two conditions: (1) This equipment may not cause harmful interference, and
(2) this equipment must accept any interference received, including interference that
may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC rules. These limits are designed to
provide reasonable protection against harmful interference in a residential installation.
This equipment generates, uses, and can radiate radio frequency energy and, if not in-
stalled and used in accordance with the instructions, may cause harmful interference to
radio communications. However, there is no guarantee that interference will not occur
in a particular installation.
If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged
to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Changes or modications not covered in this Guide must be approved in writing by the
manufacturer’s Regulatory Engineering Department. Changes or modications made
without written approval may void the user’s authority to operate this equipment.
This equipment complies with ISED radiation exposure limits set forth for an
uncontrolled environment. This equipment should be installed and operated with
greater than 20cm (approx. 8”) between the radiator & your body.
Cet équipement est conforme aux limites d’exposition aux rayonnements ISED établies
pour un environnement non contrôlé. Cet équipement doit être installé et utilisé à plus
de 20 cm entre le radiateur et votre corps.
This equipment complies with ISED’s license-exempt RSSs. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference, and (2)
this equipment must accept any interference received, including interference that may
cause undesired operation.
Le présent appareil est conforme aux CNR d’ ISED applicables aux appareils radio
exempts de licence. L’exploitation est autorisée aux deux conditions suivantes: (1)
le dispositif ne doit pas produire de brouillage préjudiciable, et (2) ce dispositif doit
accepter tout brouillage reçu, y compris un brouillage susceptible de provoquer un
fonctionnement indésirable.

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This equipment is intended only for charging vehicles that do not require
ventilation during charging. Please refer to your vehicle’s owner’s manual to
determine ventilation requirements.
Do not use extender cables to increase the length of the charging cable.
Maximum length is limited to 25 feet by the National Fire Protection Agency.
Do not drag this equipment by input power cord.
Improper connection of the equipment grounding conductor can result in a risk
of electric shock. Check with a qualied electrician or serviceman if you are in
doubt as to whether the product is properly grounded.
Do not touch live electrical parts. Incorrect connections may cause electric
shock.
Do not remove cover or attempt to open the enclosure. No user serviceable
parts inside. Refer servicing to qualied service personnel.
To reduce the risk of re, replace only with same type and rating of fuse.
Do not use this device with an extension cord.
Do not operate this equipment in temperatures outside its operating range of
-31°F to +131°F (-35°C to +55°C).
Store this equipment in a clean dry place in temperatures between -40°F to
+176°F (-40°C and +80°C).
Do not exceed maximum 150V to ground.
This equipment has internal arcing or sparking parts which should not be
exposed to ammable vapors. It should not locate in a recessed area or below
oor level. Automatic reset feature provided.
Basic precautions should always be followed when using electrical products,
including the following:
• Read all the instructions before using this equipment.
• This equipment should be supervised when used around children.
• Do not put ngers into the EV connector.
• Do not uses this equipment if the exible power cord or EV cable is
frayed, has broken insulation, or any other signs of damage.
• Do not use this equipment if the enclosure or the EV connector is
broken, cracked, open, or shows any other indication of damage.
WARNING: RISK OF PERSONAL INJURY
WARNING: RISK OF PERSONAL INJURY
WARNING: RISK OF PERSONAL INJURY
WARNING: RISK OF ELECTRIC SHOCK
WARNING: RISK OF ELECTRIC SHOCK
WARNING: RISK OF ELECTRIC SHOCK
WARNING: RISK OF FIRE OR EXPLOSION
WARNING: RISK OF FIRE OR EXPLOSION
CAUTION: RISK OF DAMAGE TO THE EQUIPMENT
CAUTION: RISK OF DAMAGE TO THE EQUIPMENT
CAUTION: RISK OF DAMAGE TO THE EQUIPMENT
WARNING: RISK OF FIRE OR EXPLOSION
WARNING: RISK OF ELECTRICAL SHOCK
SAVE THESE INSTRUCTIONS

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Basic Charger-80A or
Platinum Networked-80A
Attached to the back of the charging unit
With Hook x1, Holster x1 & M4xL15 tapping
screw x2
#2 AWG Ring terminal lug x 2
#8 AWG Ring terminal lug
M6 machine screw x1
Mounting Bracket
Holster Assembly
Accessories Bag
INTRODUCTION
1.1 Product View
1.2 Box Contents
This user manual applies to “80A Level 2 AC Charger for Plug-in Electric Vehicles
(PEVs) and Battery Electric Vehicles (BEVs)”.
The Level 2 Electric Vehicle Supply Equipment (EVSE) with 80A capabilities will be
used in North America. It can provide a shorter charging time than the 32A & 40A
EVSE.
Any unauthorized modications will void the manufacturer’s warranty!
Inside the box, you will nd the following accessories:
ITEM
11
1
2
2
3
3
4
4
1
1
1
QTY NOTESDESCRIPTION
Figure 1-2
Box contents
Table 1-3
Accessories in box
Figure 1-1
Left and Right Angle. Front
1

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TECHNICAL SPECIFICATIONS
2.1 Product Specications
APPLICATION
Voltage (Vac)
Frequency (Hz)
Current (Rms)
Charging Connector
Indications
Wi-Fi
Ethernet
BLE
Cellular
RFID
Display
Data Protocol
Operation Temp.
Storage Temp.
Mounting Type
Wiring Type
Enclosure Level
Impact Resistance
Web Portal Management
Console Management
Certication
Dimension (H x W x D)
208/240VAC (-20% ~ + 15%), Single Phase
60Hz
Max. 80 A
SAE J1772 Type 1
YES
UL 1998/2231/2594
FCC Part 15B
-31°F to 131°F (-35°C ~ 55°C)
-40°F to 176°F (-40°F ~ 80°F)
Wall mount / Pedestal mount (optional)
Hard-wired
NEMA 3R
IK10
14.1”x10.6”x5.5”
802.11 b/g/n
116(L)*8.5(W)*37(H)mm, 5.57mm CHARACTER HEIGHT,
5*8 DOT MATRIX, OLED 20x2
YES
YES
FCC Part 15.225 (RFID 13.56MHz)
FCC Part 15.247 (WLAN 2.4GHz)
Energy Star
N/A
N/A
N/A
N/A
N/A
FCC Part 15.247
(Bluetooth 2.4GHz)
YES
M2M connection
(LTE CAT.M1 / CAT.NBIoT)
OCPP 1.6
FCC Part 22/24/27
ISO 14443 A/B,
ISO 15693,
NEMA interoperability protocol
N/A
N/A
N/A
N/A
• Green Steady: Ready
• Green Flashing (Fast): Authorized, wait for EV Connect
• Green Flashing (Slow): Suspend (Occupying)
• Blue Flashing (Slow): Charging
• Red Steady: Unrecoverable Fault
• Red Flashing (Slow): Recoverable Fault
• Yellow Flashing (Slow): Booting / Firmware Upgrading / Out of Service
Remark
• Fast Flash: On Time 300ms, Off Time 200ms, 2Hz
• Slow Flash: On Time 1200ms, Off Time 800ms, 0.5Hz
RESIDENTIAL
(Open Access) COMMERCIAL
(RFID Access Control) COMMERCIAL (Networked)
2
Table 2-1
Product specications chart

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PRE-INSTALLATION
3.1 Pre-installation Safety Check
3.2 Grounding Instructions
Check for transport damages.
The charging station must be installed only by a licensed electrician in accordance with
the provisions of the local electrical industry construction and should comply with
national electrical codes and standards.
Before installing the charging station, make sure you have read all of these instructions
in this manual and fully understand its contents.
Before connecting the product to the power supply, check that the power supply
voltage and current rating corresponds with the power supply details shown on the
product rating label.
Appropriate protection is required when connecting to a main switchboard. The tools
and parts used as outlined in the section “Tools & parts required for installation”.
The charging station must be grounded through a permanent wiring system or an
equipment grounding conductor. Use a wire with a dedicated grounding wire, a ring
terminal, and connect to the equipment ground terminal block for grounding.
Disconnect the power supply before installing or repairing the charging
station. Failure to do so may result in physical injury or damage to the
power supply system and the charging station.
Avoid touching or pressing the OLED screen all times, as this may result
in damage to the OLED screen.
Keep any packing materials away from children – these materials are a
potential source of danger, e.g. suffocation.
Cord extension sets are not allowed to be used.
CAUTION
CAUTION
DANGER
CAUTION
3

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3.3 Unboxing the charging station
Open the carton and remove the EPE Foam. Take out the charging unit and then remove the
mounting bracket before installing it.
Figure 1-6
Open box, remove EPE foam, take out charging unit,
remove the mounting bracket
TOOL QTY SIZE SUPPLIER NOTES
Mounting Bracket
Holster Assembly
Screws
Wire, Copper
Heat Shrink Tube
Terminal
Conduit
Philips Screwdriver
Torx Screwdriver
Hexagon Socket
Torque Wrench
1
1
1
3
3
3
1
1
1
1
1
4
222x173x9 mm
58x58x70 mm
Tapping: #12
Mechanical: M6
Mechanical: M6
2 AWG
For 2 AWG wire
1 inch
PH3
T20
5/16
40 kgf-cm min
For 2 AWG wire
Color: Red,
Black,
Green.
All Product Models
Model Accessories
Commercially Available
Commercially Available
Model Accessories
Model Accessories
Model Accessories
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Commercially Available
Fasten charging station to the wall
Hold EV charging plug
Fasten Mounting Bracket & Hook
Fasten Charging Station & Mounting Bracket
Protect wires & terminals
Protect power cable
Tighten #12 Tapping screws
Connect input wires to the terminal block
3.4 Tools & Parts Required for Installation
Table 3-3
Table of tools & parts required

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Figure 4-4
Position of SIM card socket
Figure 4-5
SIM card socket and cover
Open/Close direction
4.2 Find SIM card socket.
4.4 Open the socket then install SIM card
4.3 Insert SIM card.
Unlock the SIM Card socket(Networked Charger only)
Figure 4-6
Open the socket cover Figure 4-7
Input the SIM Card
Figure 4-2
Use at tip screwdriver to push
snap then open front cover plate
INSTALLATION STEPS
4.1 Disassemble top cover
Figure 4-1
Loosen (1) M4 Screw
Figure 4-3
Loosen (5) M4 screws then
open install cover
4

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4.5 Secure the main body mounting bracket to the wall* with
appropriate screws.
4.6 Fasten charging station onto mounting bracket.
Follow applicable accessibility requirements for the mounting position. The unit shall be
stored or located at a sufcient height. For indoor site, it is not lower than 18” (450 mm) and
not higher than 48” (1.2m). For outdoor site, it is not lower than 24” (600 mm) and not
higher than 48” (1.2m). Refer to Article 625, NEC.
The mounting bracket has ten screw holes. If only two screws be used to fasten the mounting
bracket, the screws should pass through the middle two screw holes of the mounting
bracket. The other screw holes are reserved for the user.
*If mounting to a pedestal, follow pedestal installation manual.
Screw sizing suggestion:
a) For masonry walls, use M6
mechanical screws.
b) For nished walls supported by
wood studs, use #12 tapping screws.
c) See torque chart below
(be sure to use torque appropriate
for desired mounting surface)
SCREW
SCREW
M6
M6
#12
21.7 lb-in min
25.6 lb/in
21.7 lb-in min
25 kgf.cm min
30 kgf.cm
25 kgf.cm min
TORQUE
TORQUE
Figure 4-8
Fasten mounting bracket
Figure 4-9
Screw holes of mounting bracket
Figure 4.10
Charging station and mounting bracket
Put the charging station on the mounting bracket.
Fasten charge point on mounting bracket by tightening M6 screw. See torque chart.
Figure 4.11
Tighten M6 screw

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The clamp point is covered by heat shrink tube for protection.
Refer to the following wire specication below. Use conductor type other than RHH,
RHW and RHW-2 with outer covering.
Fold the wire end to pass through the conduit and insert them into the input hole
(choose input direction 1 or 2 and open cap).
INPUT POWER CORD INSTALLATION
5.1 Choose the appropriate conduit
in accordance with all applicable
state, local, and national electrical
codes & standards.
5.2 Clamp copper terminal to connect copper wire.
5.3 Electrical wiring to the charging station.
Figure 5-1
Conduit
5
MODEL
PowerCharge™
Energy Series
80 AMP
L1, L2
G
2 AWG 90C
copper wire
8 AWG
TERMINAL CONDUCTOR RATING
Figure 5-2
Copper terminal, heat shrink
tube, and copper wire.
Figure 5-3
Cable input position

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Use the following torque to connect the wire terminal to the terminal block.
Figure 5-4
Input wiring position
SCREW
SCREW
SCREW
M6
1”
M4
25.6 lb/in
30.36 lb-in
12 lb-in
30 kgf.cm
35 kgf.cm
15 kgf.cm
TORQUE
TORQUE
TORQUE
Fasten the copper wire on the corresponding terminal block. The wiring instruction is
printed in front of the terminal block (L1/L2/G).
Please refer to the torque chart.
Fasten M4 screw & refer to torque chart.
To reduce the risk of re, connect only to a circuit provided with 100 amperes
maximum branch circuit overcurrent protection in accordance with the National
Electrical Code, ANSI/NFPA 70, and the Canadian Electrical Code, Part I, C22.2.
If this unit is installed outdoors, the outlet must be rated for outdoor installation. The
outlet must be installed properly to maintain the proper NEMA rating of the enclosure.
CAUTION
CAUTION
5.4 Electrical wiring to the charging station.
5.5 Lock the conduit on the enclosure
5.5 Reassemble instant cover and front cover

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For nished walls supported by wood
studs, use (2) screws (#12 tapping or M6).
The recommend torque is 21.7 lb-in
(25 kgf.cm).
The recommend torque is 5.2 lb-in (6 kgf.cm).
INSTALLING THE HOLSTER
6.1 Separate the
holster from the hook.
6.2 Fasten the hook on the
wall with appropriate screws.
6.3 Turn the holster face up
and combine with the hook.
6.4 Rotate the holster down.
6.5 Maintain holster position
and tighten screws.
6.6 Place EV charging plug
on the holster.
6
Figure 6-1
Separate the holster
Figure 6-2
Secure the hook
Figure 6-3
Secure the holster
Figure 6-5
Tighten screws
Figure 6-4
Rotate the holster
Figure 6-6
Place EV charging plug

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OPERATIONS
CHARGING YOUR ELECTRIC VEHICLE
7.1 Charging Status Indicators
8.1 Plug and Charge (Open Access)
8.2 RFID Card
(Networked Version Only)
8.3 Stop charging
7
8
LED INDICATOR DESCRIPTION DEFINITION
Not illuminated
Steady Green
Flashing Green
Flashing Blue
Flashing Red
Flashing Yellow
Steady Red
Steady Purple
Power Off
Ready
Flashing green (Fast): Authorized, wait for EV connection
Flashing green (Slow): Suspend (Occupying)
Flashing blue (Slow): Charging
Recoverable Fault
Booting / Firmware Upgrading / Out of Service
Unrecoverable Fault
Reserved (from OCPP Service)
1. Insert the charging plug into the EV
2. Charging session started
1. Insert the charging plug into the EV
2. Swipe card
3. Waiting for authorization
4. Charging session begins
1. Unplug any time (disconnect the charging
plug from EV to stop charging session)
2. Session ended, return the connector to
the holster
Figure 8-1
Connect the charging plug to the EV

PowerCharge™
500 Canal View Blvd, Suite 100
Rochester, NY 14623
PowerChargeEV.com | [e-mail] | 585-533-4085
PC300-PRD310-202301-REV-A