SUN COUNTRY EV40R User manual

EV-40R Manual
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BRINGING SUSTAINABILITY TO LIFE
User’s Manual!
EV40R Rugged EVSE

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PLEASE NOTE
This user’s manual includes the latest information at the time of printing. Sun Country
Highway Ltd. reserves the right to make changes to this product without further notice.
Changes or modifications to this product by other than an authorized service facility
may void the product warranty.
If you have questions about the use of this product, contact your customer ser- vice
representative. Refer to the Customer Support section located in this guide.

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EV User’s Manual, Version 6, June 2016 EV User Manual 06082016.indd Copyright© 2016. Sun
Country Highway Ltd. All rights reserved. Printed in the USA.

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CONTENTS
IMPORTANT SAFETY INSTRUCTIONS 5
ADDITIONAL SAFETY INFORMATION 7
FCC INFORMATION 8
OPERATION 8
THE EV FRONT PANEL 9
INSTALLATION 10
SERVICE CONNECTIONS 10
MOUNTING PROCEDURES 14
MOUNTING THE CONNECTOR HOLSTER 17
WIRING INSTRUCTIONS (Hardwired EV) 19
RECEPTACLE INSTRUCTIONS 19
CHARGE CABLE WRAP GUIDELINES 20
GROUNDING INSTRUCTIONS 20
MOVING & STORAGE INSTRUCTIONS 21
CHARGEGUARD ENABLED EV INSTRUCTIONS 22
MAINTENANCE 23
CUSTOMER SUPPORT 23
SPECIFICATIONS 24
WARRANTY INFORMATION 25

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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 affixed to the
charge station:
This means pay particular attention. Notes contain helpful suggestions.
Cela signifie 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 signifie 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 signifie 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 the EV, basic electrical safety precautions should be followed:
• Use this charge station to charge electric vehicles equipped with an SAEJ1772tm
charge port only. Consult the vehicle owner’s manual to determine if the vehicle
is equipped with the correct charge port.
• Make certain the charge station 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 charge station yourself.
• Do not operate your charge station if it or the SAE-J1772tm charge cable is
physically open, cracked, frayed, or otherwise visibly damaged. Contact your
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 COMMERCIAL GARAGE is
defined as a facility (or portion thereof) used for the repair of internal
combustion vehicles in which the area may be classified due to flammable
vapors being present (such as from gasoline.)

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• Do not place fingers inside of the coupler end of the SAE-J1772tm charge cable.
• Do not allow children to operate this device. Adult supervision is mandatory
when children are in proximity to a charge station that is in use.
Instructions se Rapportant à un Risque d’Incendie ou de Choc Électrique
Lorsque l’utilisation de la EV, 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 afin de déterminer si le véhicule est équipé d’un correcte
port de recharge.
• Assurez-vous que le SAE-J1772tm câble de recharge sur la station de re- charge
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 recharge si elles sont
physiquement ouverte, fissuré, effiloché, ou autrement visiblement endom-
magé. Contactez 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 commercial est défini
comme une installation (ou une partie) utilisé pour la réparation de véhicules à
combustion interne dans lequel la zone peut être classée en raison de vapeurs
inflammables étant présents (Tels que de 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.
•
•

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ADDITIONAL SAFETY INFORMATION
WARNING: Turn off input power to your charge station 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.
NOTE
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.
NOTE
Vehicles which conform to the SAE-J1772tm standard for communication can
inform the charge station that they require an exhaust fan. The EV is not
equipped to control ventilation fans. Do not charge the vehicle with the EV 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 EV n’est pas équipé pour contrôler les ventilateurs. Ne chargez
pas le véhicule avec les EV 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.

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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 your charge station is suspected, we suggest the following steps be
taken before consulting your Sun Country Highway Sales and 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: Changes or modifications to this product by other than an
authorized service facility may void FCC compliance.
ATTENTION: Modifications apportées à ce produit par qui conque autre qu’un
centre de service autorisé peut annuler la conformité FCC.
OPERATION
The EV Electric Vehicle Charging Station is a compact wall or pedestal-mount- ed
charging station 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 (EV) and NEMA plug-equipped (EV-40P)
versions are available.
The EV is very easy to use. Just unwrap the SAE-J1772tm charge cable and plug the
charge coupler firmly into the vehicle’s charge port.
Normally, the vehicle will immediately request a charge using a special commu-
nication line in the cable. Within a few seconds the green “Charging” light on the face
of the EV will turn on and the charging cycle will begin. After an aver- age 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 EV will turn
off. To remove the charge coupler once a charge cycle has completed (or to interrupt a
charge in progress) press and hold down the latch release lever on the charge coupler
handle then unplug the charge coupler from the vehicle charge port.

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THE EV FRONT PANEL
Figure 1. Front Panel
The front panel on the EV has four indicator
lights, as shown in Figure 1:
POWER (yellow), indicates that power is
available to the EV.
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 EV
is not wired correctly. The problem can
be due to improper grounding or a
missing Earth Ground. The wiring
should be examined by a qualified
electrician.
CHARGING FAULT (red), indicates that
the EV is unable to communicate with the
vehicle correctly, or a safety fault condition
has been detected by the unit.
Table 1. Front Panel LED Information

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INSTALLATION
SERVICE CONNECTIONS
CAUTION: To reduce the risk of fire, connect only to a circuit provid- ed 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’électric- ité 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 center-point of the three phases (usually used as Neutral)
must be grounded somewhere in the system. A Neutral connection is not
required by the EV. Only Line 1, Line 2, and Ground are required, as shown in
Figure 3.
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 EV.
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 second-
ary,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 on
page 12.
ATTENTION: Si une alimentation à triphasé 240V provient d’un trian- gle
connecté secondaire, la bornes utilisée doit avoir un centre-tap. Que la tap doit
EV Model
EV Model
EV Model
EV Modèle
EV Modèle
EV Modèle
EV-40 (Hardwired)
40A
n/a
EV-40P + NEMA 14-50P
50A
NEMA 14-50R
EV-60 (Hardwired)
60A
n/a

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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-des- sous.
CAUTION: Warranty is void if this unit is not wired properly
ATTENTION: La garantie est annulée si cette unité n’est pas cor-
rectement câblé
WARNING: Only a qualified electrician should perform the installation. The
installation must be performed in accordance with all local electri- cal codes
and ordinances.
AVERTISSEMENT: Seul un électricien qualifié doit effectuer l’instal- lation.
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 definitely known, and the 3 wires from the main circuit breaker
panel are connected and labeled correctly. Figures 2, 3, and 4 below show the most
common service transformer secondary wiring formats.
Notice that L1, L2, & Ground are labeled on each diagram. Those transform- er outputs
correspond to the same inputs on the EV. 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 EV. 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 pro- tection 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 ser- vice, 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.
The following diagrams illustrate the three service transformer secondary
connections most common in North America.

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Figure 2 - 220/240V Single Phase
!
Figure 3 - 208V 3-Phase, Wye-Connected
NOTE
With a wye-connected secondary, any two of the legs can be used to provide
208V to the EV. For example, L1 & L2, or L1 & L3, or L2 & L3. Leave the

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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 EV. 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.
Figure 4 - 240V 3-Phase, Delta-Connected, with center-tap on one leg
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 centre- tapped,
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.

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CAUTION: A 3-phase delta-connected transformer secondary without a
center-tap on one leg cannot be used with the EV. No “Neutral” point is
available to be connected to ground for ground-fault protection. The EV 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 EV. Aucun point
“Neutre” est disponible pour être connecté à Mise à la Terre pour protection de
défaut à la terre. Le EV ne
permettra pas le contacteur de fermer si elle ne détecte pas la présence d’un fil
de Masse connecté à un point “Neutre” sur le secondaire du transformateur.
MOUNTING PROCEDURES
Locate the wall mounting position of the EVSE:
¥ On the hardwired EV, the three service conductors are shielded by three feet of
flexible conduit. The EV must be positioned such that this conduit can reach a
nearby junction box.
¥ On the plug-in EV-40P, the NEMA plug head is connected by one foot of cable
(including the plug head) to the bottom side of the EV-40P. The
EV-40P must be positioned such that this plug can safely be inserted into a
wall-mounted NEMA socket.
¥ Position the bottom of the charge station 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 anyone who will be operating the device.
¥ The EV 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 charge station 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."

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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 ply- wood.
¥ Size ¼-20 lag screws are recommended for mounting the EV 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 solid flat backing to the screw head.
¥ If the screw head is smaller than the 3/8” washer aperture, an additional flat washer
will need to be placed between the 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 anchor- ing hardware
such as drywall toggles or molly bolts.
Figure 5. Mounting the EV to a hollow wall

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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 than the 3/8” plastic
angle washer aperture, an additional flat 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 EV.Screw
shafts of at least 2” are recommended. The EV plastic angle washer hole size is
3/8” in diameter, so ensure that the screw heads are of a larger diameter. Place
appropriately sized washers between the screw heads and the EV enclosure
mounting flanges.
Figure 6. Mounting the EV to a solid wall

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MOUNTING THE SAE-J1772TM
CONNECTOR HOLSTER
The SAE-J1772tm connector holster is included to provide a convenient protec- tive
housing for the the SAE-J1772tm connector head when it is not in use.
¥ The SAE-J1772tm connector holster should be placed so that users have easy and
safe access to the SAE-J1772tm connector.
¥ For indoor installation, mount the SAE-J1772tm connector holster between 18 and 48
inches above the ground or grade.
¥ For outdoor installation, mount the SAE-J1772tm connector holster between 24 and
48 inches above the ground or grade.
¥ The SAE-J1772tm connector holster has two vertically aligned mounting holes
spaced 5.45” apart, one each on the enclosure top and bottom. Use a ruler or
template to mark hole locations on the mounting surface.
¥ The vertical alignment of the EV and SAE-J1772tm connector holster mounting
holes allows for the convenient mounting of both components onto the same post or
wall structure. For example, the holster may be mounted directly above the EV.
¥ Place the SAE-J1772tm connector holster such that both mounting holes can take
advantage of solid structural framing inside of the wall or a strong wall surface
such as plywood.
¥ A set of exterior wood screws and stainless steel washers are included for the
purposes of mounting the SAE-J1772tm connector holster to a wooden surface.
¥ For mounting to a solid surface such as concrete, brick, or stone, alternate hardware
may need to be procured. Examples of solid-wall mounting hard- ware include
muti-sets, wedge anchors and sleeve anchors. Use the type of mounting hardware
most appropriate for the supporting structure.
Figure 7. Mounting the holster using the exterior wood screws and washers

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WIRING INSTRUCTIONS
(Hardwired EV)
Route the EV conduit to a nearby junction box. Use the included ½” trade size
watertight conduit fitting and sealing washer to provide a moisture-resistant seal
between the conduit fitting and the junction box. If necessary, drill a 7/8”diame- ter
hole to accommodate the conduit fitting. For outdoor installations ensure the junction
box is fully sealed using appropriate electrical grade silicone sealant.
Before connecting the EV service conductors, please carefully read the section of this
manual titled Service Connections on page 9. If you are unsure of the type of power
provided at the service panel, please consult with your local utility or call your Service
Representative for assistance.
Figure 8. Wiring the EV in a junction box
The three supplied EV-20, 25, 30 or 40 EV-40 service
conductors use stranded 10 AWG 75ºC copper wire.
The three supplied EV-50, and EV-60 service con-
ductors use stranded 8 AWG, 75ºC copper wire.
The insulation of each conductor is color coded for
standard 240VAC installation:
Green: Ground
Black: Line 1 (120VAC to Ground) Red: Line 2
(120VAC to Ground)
Les trois EV-20, 25, 30 un EV-40 service conduc- teurs
fournis utilisent bloqués câble en cuivre 10 AWG 75ºC.
Les trois EV-50 fournis et conducteurs EV-60 uti-
lisent des services bloqués 8 fil de cuivre AWG, 75ºC.
L’isolation de chaque conducteur est un code couleur
pour l’installation de 240VAC norme:
Ver t : Mise à la Terre
Noir: Ligne 1 (120VAC à Mise à la Terre) Rouge:
Ligne 2 (120VAC à Mise à la Terre)

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RECEPTACLE INSTRUCTIONS (Plug-In
EV-40P)
The EV-40P is fitted with either a NEMA 14-50P or 6-50P plug extending from the
bottom of the EV enclosure. Regulations limit this plug to a maximum of 12 inches in
length, including the plug head. For this reason, the EV-40P must be mounted above the
NEMA receptacle and must also be located within 12 inches of it. The EV-40P is rated
for indoor only, unless in a weather proof inclosure compliant with electrical code.
In both NEMA 14-50P and 6-50P configurations, the ground pin is located at the
furthest point on the plug. With this in mind, it is recommended that a NEMA 14- 50R
or 6-50R receptacle be oriented accordingly, such that the ground sock- et is at the
lowest point.
Figure 9. Preferred orientation of the NEMA receptacles below the EV-40P