Tesla HOME CONNECTOR User manual

ClipperCreek Inc.
Users Manual
HOME CONNECTOR
Home Connector Users Manual.book Page 1 Monday, April 26, 2010 12:38 PM

Table of Contents
Part Number: 6005822 Rev AA
©2010 TESLA MOTORS INC. All rights reserved.
This material may not be reproduced or copied, in whole or in part, without the written permission of Tesla Motors, Inc.
Safety and regulatory information
Warnings and cautions 1
FCC Declaration of Conformity 1
Features and specifications
Features 2
Specifications 3
Utility service connections
120V above ground 4
230V above ground 6
Installation
Installing the Home Connector 7
Electrical connection
120V above ground 8
230V above ground 9
Post-installation testing
Confirming a successful installation 10
Operating instructions
Home connector front panel 11
Front panel indicator lights 11
In case of difficulty 12
Vehicle charging instructions 12
Maintenance, Warranty, and Service
Maintenance 13
Warranty 13
Customer service 13
For the service technician
GFCI (CCID) trip 14
Ground missing 14
Home Connector Users Manual.book Page 1 Monday, April 26, 2010 12:38 PM

Safety and regulatory information
1
Charging your vehicleSafety and regulatory information
Warnings and cautions
WARNING: The Home Connector
must be installed by a qualified
electrician and in accordance with all local
electrical codes and ordinances. ▲
WARNING: The Home Connector
must be grounded through a
permanent wiring system or an equipment
grounding conductor. Failure to properly
ground the Home Connector could result
in fire, serious injury, or death. ▲
WARNING: Do not install the Home
Connector near flammable,
explosive, or combustible materials. ▲
WARNING: Do not operate a Home
Connector with a visibly damaged
cable. Contact Tesla Motors immediately. ▲
WARNING: The Home Connector
contains no user-serviceable parts.
Do not attempt to repair or service the
Home Connector yourself. If the Home
Connector requires servicing, contact
Tesla Motors. ▲
Caution: When transporting the
Home Connector, handle with care
to prevent its internal components from
being damaged.
Caution: Incorrect installation and
testing of the Home Connector
could result in damage to the vehicle’s
Battery and to the Home Connector itself.
These damages will void the warranty for
the vehicle and the Home Connector.
Caution: Do not operate the Home
Connector in temperatures outside
its operating range of -40°F to 122°F
(-40°C to +50°C).
Caution: Ensure that the Home
Connector’s charge cable is
positioned so it will not be stepped on,
tripped over, or subjected to damage or
stress.
Environmental considerations
At the end of its life, this product
should be recycled according to
local laws and regulations. Contact Tesla
Motors for recycling information.
Product specification
All specifications and descriptions are
accurate at the time of printing. Because
improvement is a constant goal at Tesla
Motors, we reserve the right to make
changes at any time, without notice and
without obligation.
FCC Declaration of Conformity
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.
Radio and television interference
The equipment described in this manual
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 operations.
If interference to your Home Connector is
suspected, relocate or turn off nearby
electrical appliances during charging,
before contacting Tesla Motors for
assistance.
Important!
Changes or modifications to this product
not authorized by Tesla Motors could void
the FCC compliance.
SAVE THESE IMPORTANT
SAFETY INSTRUCTIONS
This manual contains important
instructions that must be followed
during the installation, operation, and
maintenance of the Home Connector.
Home Connector Users Manual.book Page 1 Monday, April 26, 2010 12:38 PM

Features and specifications
2
Features and specifica tions
Features
The Home Connector features ground
fault protection with self-testing and
auto-reclosure (see below).
Note: Manual resetting or testing is not
required.
Ground monitoring circuit
The Home Connector features a ground
monitoring circuit that continuously
checks for the presence of a safe ground
connection.
Auto-reclosure
If a problem occurs that interrupts
charging, the Home Connector will
automatically clear the error condition
and re-attempt charging.
If a problem is immediately sensed a
second time, the Home Connector will
wait 13 minutes before re-attempting to
charge. This process will repeat several
times.
After several unsuccessful attempts, no
further charging attempts will be made
and the appropriate front panel indicator
light will be illuminated to indicate the
nature of the failure (see Front panel
indicator lights, page 11).
This feature helps to ensure that your
vehicle will be charged and ready for use
when needed. Temporary problems such
as ground faults or utility power surges
will be overcome automatically, without
your attention.
Cold load pickup
This feature is activated if the utility power
fails during charging.
Providing the charging cable is plugged
into the vehicle when utility power is
restored, the Amber CHARGING light will
blink and the unit will delay energizing the
cable for a period between 2 and 12
minutes. This prevents the utility grid from
experiencing a large surge at turn-on,
allowing electric vehicles in the area to
begin drawing current at random times,
rather than all at once.
If desired, you can manually resume
charging by pressing and holding the
START button on the front panel.
Note: If a power outage occurs, the Home
Connector will automatically try to resume
charging when power is restored.
Home Connector Users Manual.book Page 2 Monday, April 26, 2010 12:38 PM

Features and specifications
3
Specifications
Voltage and wiring
(120V above ground)
240V AC single-phase: L1, L2, and Safety Ground
208V AC 3-phase, wye-connected: Any 2 phases, and safety ground.
240V AC 3-phase, delta-connected: With center tap on one leg, use only the
two phases on either side of the center tap. The two phases must both
measure 120V AC to ground. Do not use the third leg (208V “stinger”).
Voltage and wiring
(230V above ground)
230V AC single-phase: LINE, NEUTRAL, and EARTH.
Current and frequency 90A Circuit Breaker. The maximum current for the vehicle is 70A. At 240V,
this will be 17 kW maximum. At 230V, this will be 16 kW maximum. The
frequency is 50-60 Hz.
Cable length Approximately 25’ (7.6 m)
Dimensions Height: 14” (363 mm)
Width: 17” (432 mm)
Depth: 6” (152 mm)
Weight Weight: 47 lbs (21 kg)
Operating temperature -40°F to 122°F
-40°C to 50°C
Ratings and agency
approvals
NEMA 4 - outdoor use, watertight.
UL and CSA approved. CE compliant. FCC Part 15 compliant.
Home Connector Users Manual.book Page 3 Monday, April 26, 2010 12:38 PM

Utility service connections
4
Utility service connections
120V above ground
WARNING: The Home Connector is a
single-phase device. Do not connect
all 3 phases of a 3-phase feed. ▲
The following types of service connection
are primarily used in North America.
IMPORTANT! Before commencing on the
installation of the Home Connector it is
important you correctly identify the type
of utility service connection available on
site. If you are unsure about the type of
connection available at the service panel,
consult the local utility company, or
contact Tesla Motors for assistance.
Only three wires are connected, but care
must be taken that the service
transformer secondary connection is
definitely known, and the three wires from
the main circuit breaker panel are
correctly connected and labeled. The
illustrations in this section show the most
commonly used wiring formats.
Note: The L1, L2, and GND outputs in the
following illustrations correspond to the
inputs on the Home Connector.
Ground (Earth) connection
Always connect the Neutral at the service
to earth ground. Ground fault protection is
not possible unless the Neutral (center tap
on the service transformer) is connected
to an earth ground.
If ground is not provided by the electrical
service, you must install a grounding stake
nearby.
The grounding stake must be connected
to the ground bar in the main breaker
panel, and Neutral connected to ground at
that point.
WARNING: Always follow local
electrical codes when installing the
grounding stake. ▲
220/240V Single Phase
120V
120V
NEUTRAL
(NOT USED)
L1
L2
GND
240V
208V 3-Phase, wye-connected
With a wye-connected secondary, any two
of the legs can be used to provide 208V to
the Home Connector. For example, L1 and
L2, or L1 and L3, or L2 and L3.
Caution: The unused leg (L3 in the
illustration) must remain open. Do
not connect to a Neutral bar, or to Ground.
The two used phases must each measure
120V to Neutral.
Caution: The center point of the 3
phases (normally used as Neutral)
must be grounded to earth at only one
point. This is usually at the Service Entry
Breaker Panel
Note: A current-carrying Neutral is not
required.
120V
120V
NEUTRAL
(NOT USED)
GND
L1
L2
L3 (NOT USED)
208V
Home Connector Users Manual.book Page 4 Monday, April 26, 2010 12:38 PM

Utility service connections
5
240V 3-Phase, delta-connected,
with center tap on one leg
With the delta connection, one leg must
be center tapped, and only the two phases
on either side of the center tap can be
used.
The third line (L3 in the illustration)
of the delta is 208V, with respect to
neutral, and is sometimes referred to as a
“stinger.” Do not use this third line.
The two used phases must each measure
120V to neutral.
Consult the transformer manufacturer’s
literature to verify that the single leg can
supply the required power.
Caution: Do not use a 3-phase
delta-connected transformer
secondary without a center tap on one
leg. No “neutral” point is available for the
required ground connection.
Note: The Home Connector’s contactor
will only close if it detects the presence of
a ground wire connected to a neutral point
on the transformer secondary.
L3 (NOT USED)
L1
L2
GND
NEUTRAL
(NOT USED)
120V
120V
240V
Home Connector Users Manual.book Page 5 Monday, April 26, 2010 12:38 PM

Utility service connections
6
230V above ground
WARNING: The Home Connector is a
single-phase device. ▲
The following types of service connection
are primarily used in Europe and Australia
(sometimes known as “TT Power Grid”).
IMPORTANT! Before commencing on the
installation of the Home Connector it is
important you correctly identify the type
of utility service connection available on
site. If you are unsure about the type of
connection available at the service panel,
consult the local utility company, or
contact Tesla Motors for assistance.
When connecting the Line and Neutral
wires, care must be taken that the service
transformer secondary connection is
definitely known, and the wires from the
main circuit breaker panel are correctly
connected and labeled. The illustration
provided on this page shows the most
commonly used wiring format in Europe.
Note: The LINE, NEUTRAL, and EARTH
outputs on the following illustration
correspond to the inputs on the Home
Connector.
Ground (Earth) connection
Always connect the Neutral line at the
service panel to Earth. Ground fault
protection is not possible unless the
Neutral line is connected to Earth.
If an Earth connection is not available, you
must install a grounding stake nearby.
The grounding stake must be connected
to the ground bar in the main breaker
panel, and Neutral connected to Earth at
that point.
WARNING: Always follow local
electrical codes when installing the
grounding stake. ▲
230V Single Phase
Caution: The LINE connection must
measure 230V RMS to NEUTRAL.
EARTH must also be connected to the
Home Connector.
NEUTRAL
LINE
EARTH
230VAC
Home Connector Users Manual.book Page 6 Monday, April 26, 2010 12:38 PM

Installation
7
Installation
Installing the Home Connector
Note: Dimensions above are shown in
inches. 1 inch = 2.54 cm.
1. Locate the wall mounting position:
•The bottom of the Home Connector
must be positioned 38 inches (1 meter)
above the ground.
•The mounting holes are spaced 16”
(40.6 cm) apart to accommodate wall
studs.
In the absence of solid structural
framing, you must provide an
adequate mounting surface.
2. Attach the Home Connector to the wall
studs using four 1/4” x 2 1/2” (M6) lag
screws. The length of the screws must
be adequate to securely anchor the
Home Connector.
If mounting on a concrete wall, use a
multi-set (or equivalent).
3. Remove the applicable power entry
knock-out from the Home Connector,
push the power leads through the hole,
then connect the power conduit to the
hole.
Continue the installation by following the
electrical connection procedure, provided
next.
Home Connector Users Manual.book Page 7 Monday, April 26, 2010 12:38 PM

Electrical connection
8
Electrical connection
120V above ground
WARNING: Before commencing any electrical installation, always make sure that the
electricity supply has been isolated at the main circuit breaker panel. ▲
Note:The following connection details described here are primarily used in North America.
To access the electrical connections, open
the enclosure by removing the two screws
on the left-hand side using a T15 Torx L
driver. Then unhook the latch located on
the bottom of the unit (over the cable
holder).
Caution: Before connecting any
wires, make sure you have identified
the type of utility service connection
available. For more information, refer to
Utility service connections, page 4.
ClipperCreek, Inc.
READY
CHARGE
PROTECT
SERVICE
VEHICLE
GROUND
TERMINAL
L1
L2
GND
CONTACTOR
Service Side
Vehicle Side
Note:
•The Home Connector requires a
dedicated 208/240 VAC 60 Hz,
single-phase circuit, with its own 90A
circuit breaker.
•Do not use a GFCI breaker. The Home
Connector contains a Personal
Protection circuit specifically designed
for use with electric vehicles.
•Only 3 wires are required (L1, L2 and
GND), as shown in the illustration.
For branch circuits of 90A, use 4 AWG,
75°C copper wire. For installations less
than 90A, use conductors sized
according to Table 310.16 of NEC, or in
accordance with local electrical codes.
•The two phases (L1 and L2) are
terminated on the input side of the
CONTACTOR. The ground (GND) is
terminated on the Ground Terminal at
the bottom of the enclosure.
•Be careful not to damage the PC Board
when removing the power entry
knock-out, attaching the conduit, or
when wiring the service conductors to
the contactor.
Installation is complete. Before securing
the enclosure, perform the
post-installation testing procedure
described on page 10.
Home Connector Users Manual.book Page 8 Monday, April 26, 2010 12:38 PM

Electrical connection
9
230V above ground
WARNING: Before commencing any electrical installation, always make sure that the
electricity supply has been isolated at the main circuit breaker panel. ▲
Note: The following connection details described here are primarily used in Europe and
Australia.
To access the electrical connections, open
the enclosure by removing the two screws
on the left-hand side using a T15 Torx L
driver. Then unhook the latch located on
the bottom of the unit (over the cable
holder).
Caution: Before connecting any
wires, make sure you have identified
the type of utility service connection
available. For more information, refer to
Utility service connections, page 4.
ClipperCreek, Inc.
READY
CHARGE
PROTECT
SERVICE
VEHICLE
GROUND
TERMINAL
LINE
NEUTRAL
EARTH
CONTACTOR
Service Side
Vehicle Side
Note:
•The Home Connector requires a
dedicated 230 VAC 50Hz, single-phase
circuit, with its own 90A circuit breaker.
•Do not use a GFCI breaker. The Home
Connector contains a Personal
Protection circuit specifically designed
for use with electric vehicles.
•Only 3 wires are required (LINE,
NEUTRAL, and EARTH), as shown in
the illustration.
For branch circuits of 90A, use 4 AWG,
75°C copper wire. For installations less
than 90A, use conductors sized
according to local electrical codes.
•The LINE and NEUTRAL lines are
terminated on the input side of the
contactor. The EARTH line is
terminated on the Service Earth
terminal at the bottom of the enclosure.
•Be careful not to damage the PC Board
when removing the power entry
knock-out, attaching the conduit, or
when wiring the service conductors to
the contactor.
Installation is complete. Before securing
the enclosure, perform the
post-installation testing procedure
described on page 10.
Home Connector Users Manual.book Page 9 Monday, April 26, 2010 12:38 PM

Post-installation testing
10
Post-installation testing
Confirming a successful
installation
Apply utility power and observe that only
the green READY light illuminates.
Two “Charge Test” buttons on the PC
board (arrowed in illustration) simulate
connection to a vehicle.
Push both buttons at the same time and
verify that the contactor closes, and the
amber CHARGING light illuminates.
If a vehicle is available, connect the Home
Connector to the vehicle and verify that
the contactor closes, and the amber
CHARGING light illuminates.
Once a successful installation has been
confirmed, close the Home Connector’s
enclosure door and secure the latch.
Reinsert the two Torx screws on the
left-hand side and hand tighten them with
a T15 Torx L driver until snug.
ClipperCreek, Inc.
READY
CHARGE
PROTECT
SERVICE
Home Connector Users Manual.book Page 10 Monday, April 26, 2010 12:38 PM

Operating instructions
11
Operating instructions
Home connector front panel
The front panel on the Home Connector
has four indicator lights:
•READY - illuminates green to indicate
that the unit is receiving power.
•CHARGING - illuminates amber when a
vehicle is being charged.
To stop charging, push the STOP
button on the bottom of the panel
before disconnecting the charge cable
from the vehicle.
•PROTECTION - illuminates red if a fault
has occurred.
•SERVICE - illuminates red if a fault has
occurred.
Front panel indicator lights
GREEN
READY
LIGHT
AMBER
CHARGING
LIGHT
RED
PROTECTION
LIGHT
RED
SERVICE
LIGHT CONDITION
OFF OFF OFF OFF No service power
ON OFF OFF OFF Home Connector has power
but the vehicle is either not
connected, or has not
requested a charge
ON ON OFF OFF Vehicle is charging
ON Blinking OFF OFF Cold load pick-up mode (see
page 2). To bypass, press the
START button on the Home
Connector’s front panel.
ON OFF OFF ON (Steady) Ground monitor interrupt
ON OFF ON (Steady) OFF Charging fault on vehicle
ON OFF 1 Blink OFF Ground fault on vehicle
ON OFF 2 or more
Blinks
2 or more
Blinks
Service needed. Contact Tesla
Motors.
Home Connector Users Manual.book Page 11 Monday, April 26, 2010 12:38 PM

Operating instructions
12
In case of difficulty
Tesla Motors understands that you will rely
heavily on the Home Connector to charge
your Roadster. Therefore, should problems
arise, every effort will be made to restore
service as soon as possible. To minimize
unnecessary wait time if charging stops
and either the red PROTECTION or red
SERVICE lights illuminate, follow these
steps before contacting Tesla Motors:
•Press the START button the Home
Connector’s front panel to restart
charging.
•If the red PROTECTION or SERVICE
light remains illuminated, unplug the
vehicle. If the red light goes out, plug
the vehicle back in and see if charging
begins normally.
•If charging does not begin normally
and the red PROTECTION or SERVICE
light continues to illuminate, unplug
the vehicle and switch power off at the
circuit breaker. Wait a few seconds and
switch the breaker back on again. If the
PROTECTION or SERVICE light does
not come back on, plug the vehicle
back in. Charging should begin
normally.
If charging does not begin after following
these steps, contact Tesla Motors.
Vehicle charging instructions
For detailed information on how to charge
your Tesla Roadster, refer to the ‘Owner’s
Manual’.
Home Connector Users Manual.book Page 12 Monday, April 26, 2010 12:38 PM

Maintenance, Warranty, and Service
13
Maintenance, Warranty, and Servi ce
Maintenance
WARNING: The Home Connector has
no user-serviceable components
within it. If the unit is not operating
correctly, please contact Tesla Motors. ▲
The Home Connector requires no periodic
maintenance other than the occasional
cleaning.
Always ensure that after charging, the
charging cable is returned to the cable
hanger and the charging connector is
clear of the floor.
Regularly inspect the Home Connector
and charging cable for signs of damage. If
damage is found, contact Tesla Motors.
Cleaning Instructions
WARNING: Turn off input power at
the circuit breaker before cleaning
the Home Connector. ▲
WARNING: Do not use cleaning
solvents, scouring powder, or any
type of abrasive pad to clean the Home
Connector, its charging cable or the
vehicle’s charging port. ▲
WARNING: To reduce the risk of
electrical shock or equipment
damage, do not allow liquid to enter the
Home Connector while cleaning it. ▲
The outside of the Home Connector, the
charging cable, and the connector end of
the charging cable should be regularly
cleaned with a clean dry or damp cloth to
remove any accumulation of dust and dirt.
Warranty
The Home Connector is covered by a one
year parts and labor warranty. For a
detailed description of this warranty,
contact Tesla Motors.
Customer service
To obtain service for your Home
Connector, contact Tesla Motors. Have the
model and serial number ready. These can
be found on the label attached to the side
of the enclosure.
Home Connector Users Manual.book Page 13 Monday, April 26, 2010 12:38 PM

For the service technician
14
For the service technician
GFCI (CCID) trip
If the Home Connector detects a ground
fault, the contactor will open and the front
panel’s red PROTECTION light will
illuminate. The system waits 13 minutes
after sensing a fault, then automatically
attempts recovery. After several such
attempts, the Home Connector will stay in
the PROTECTION mode and the red
PROTECTION light will blink continuously.
If a ground fault error or an electric vehicle
connection error has been detected,
follow these steps:
1. Unplug the vehicle.
2. Inspect the connector and the vehicle’s
charge port to verify they are clean
and undamaged. If necessary remove
any accumulation of dust or dirt from
the charge port, or the cable
connector, using a clean dry or damp
cloth.
3. Plug the vehicle back in. If the fault
persists, contact Tesla Motors for
assistance.
Ground missing
When the Home Connector detects a
missing Service Ground (Earth
connection), the red SERVICE light on the
front panel will illuminate. The Home
Connector’s contactor will not close until a
proper Service Ground (Earth connection)
has been detected.
Home Connector Users Manual.book Page 14 Monday, April 26, 2010 12:38 PM

TESLAMOTORS.COM
Home Connector Users Manual.book Page 2 Monday, April 26, 2010 12:38 PM