SEMACONNECT 19840917 ChargePro 620 User Manual Installation Guide

SEMACONNECT INC. ChargePro 620 Installation Guide

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19840917 User Manual HTML Version

Installation Guide

ChargePro™!620$Charging$Station!

Installation

Guide

SemaConnect Inc.

175 Admiral Cochrane Dr, Suite 300

Annapolis MD 21401

www.semaconnect.com

Version 0.9D

WARNING

SemaConnect recommends that only a qualified electrical professional should

install or service electric vehicle charging station equipment.

This equipment requires a heavy load electrical connection. Before beginning work,

make certain all electrical power has been turned off, such that the electrical supply

wires are disconnected from all power sources. This may require that you contact your

electric utility to disconnect power to an existing load-center. SemaConnect will not

assume responsibility for property damage or personal injury resulting from wrong use

or inadequate safety measures in servicing this equipment.

HAZARDOUS VOLTAGE

CAN CAUSE SEVERE

INJURY

OR DEATH.

Turn off Main power before

installing or servicing this device.

3 | Page

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Install Equipment in Conformance with codes

This product must be installed in accordance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC) or any

applicable local code. Before installing the equipment do check with your local electrical authority. If you have any questions or

need assistance, contact a qualified electrical contractor.

Grounding instructions

The ChargePro™ 620 Charging Station is grounded using a dedicated grounding conductor that grounds the charging station to the

power distribution panel ground.

FCC Compliance Statement

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules.

These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial

environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with

the manufacturer’s instruction manual, may cause harmful interference with radio communications.

Important: Any Changes or modifications to this product not authorized by SemaConnect, Inc., could affect the EMC compliance and

revoke your authority to operate this product.

Exposure to Radio Frequency Energy: The radiated power output of the Zigbee radio and cellular modem (optional) in this device is

below the FCC radio frequency exposure limits for uncontrolled equipment.

Safety and compliance

This document provides instructions to install the ChargePro™ 620 Charging Station and should not be used for any other product.

Before installing the ChargePro™ 620 Charging Station, you should review this manual carefully and consult with a licensed contractor,

licensed electrician and trained installation expert to ensure compliance with local building practices, climate conditions, safety standards,

and state and local codes. The ChargePro™ 620 Charging Station should be installed only by a licensed contractor and a licensed

electrician and in accordance with all local and national codes and standards. The ChargePro™ 620 Charging Station should be

inspected by a qualified installer prior to the initial use. Under no circumstances will compliance with the information in this manual relieve

the user of his/her responsibility to comply with all applicable codes or safety standards. This document describes the most commonly-

used installation and mounting scenarios. If situations arise in which it is not possible to perform an installation following the procedures

provided in this document, contact SemaConnect. SemaConnect is not responsible for any damages that may occur resulting from

custom installations that are not described in this document.

No accuracy guarantee

Reasonable effort was made to ensure that the specifications and other information in this manual are accurate and complete at

the time of its publication. However, the specifications and other information in this manual are subject to change at any time

without prior notice.

Warranty information and disclaimer

Your use of, or modification to, the ChargePro™ 620 Charging Station in a manner in which the ChargePro™ 620 Charging

Station is not intended to be used or modified will void the limited warranty. Other than any such limited warranty, SemaConnect

products are provided “AS IS,” and SemaConnect and its distributors expressly disclaim all implied warranties, including any

warranty of design, merchantability, and fitness for a particular purposes and non-infringement, to the maximum extent permitted

by law.

Limitation of liability

IN NO EVENT SHALL SEMACONNECT, INC. OR ITS AUTHORIZED DISTRIBUTORS BE LIABLE FOR ANY INDIRECT,

INCIDENTAL, SPECIAL, PUNITIVE, OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION, LOST PROFITS,

LOST DATA, LOSS OF USE, COST OF COVER, OR LOSS OR DAMAGE TO THE CHARGEPRO™ 620 CHARGING STATION,

ARISING OUT OF OR RELATING TO THE USE OR INABILITY TO USE THIS MANUAL, EVEN IF SEMACONNECT, INC. OR

ITS AUTHORIZED DISTRIBUTORS HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

other countries. It may not be modified, reproduced or distributed without the prior, express written consent of SemaConnect, Inc.

ChargePro™ 620 Charging Station is a trademark of SemaConnect, Inc. All other products or services mentioned are the

trademarks, service marks, registered trademarks or registered service marks of their respective owners.

! !

Chapter 2.Pedestal Mount

5 | Page

"#$%&!'(!)'*+&*+,!

Chapter(1.Introduction(__________________________________________________________(7!

Pre$installation,preparation, ___________________________________________________,7!

Wiring,color,code,____________________________________________________________,8!

Specifications,_______________________________________________________________,9!

Wiring,Information,__________________________________________________________,10!

Chapter(2.Pedestal(Mount(______________________________________________________(11!

Manufacturer,Supplied,Materials,for,Installation,_________________________________,11!

Installation,Overview,________________________________________________________,11!

Step,1,$,Check,boxes,for,correct,content, ________________________________________,12!

Step,2,–,Install,Anchor,Plate, __________________________________________________,14!

Step,3,$,Install,Pedestal,Unit, __________________________________________________,16!

Step,4,–,Attach,Cable,Rack,____________________________________________________,17!

Step,5,–,Install,the,Charging,Station,Head,Unit,___________________________________,18!

Chapter3.Wall(Mount( _________________________________________________________(21!

Manufacturer,Supplied,Materials,for,Installation,_________________________________,21!

Installation,Overview,________________________________________________________,21!

Step,1,$,Check,boxes,for,correct,content, ________________________________________,22!

Step,2,–,Pre$installation,preparation, ___________________________________________,25!

Step,3,$,Install,the,Wall/Pole,Mount,Bracket,_____________________________________,27!

Step,4,–,Attach,Cable,Rack,____________________________________________________,28!

Step,5,–,Install,the,Charging,Station,Head,Unit,___________________________________,29!

Chapter4.Pole(Mount(__________________________________________________________(31!

Manufacturer,Supplied,Materials,for,Installation,_________________________________,31!

Installation,Overview,________________________________________________________,31!

Step,1,$,Check,boxes,for,correct,content, ________________________________________,32!

Charging Station Installation Guide

Step,2,–,Pre$installation,preparation, ___________________________________________,35!

Step,3,$,Install,the,Wall/Pole,Mount,Bracket,_____________________________________,36!

Step,4,–,Attach,Cable,Rack,____________________________________________________,37!

Step,5,–,Install,the,Charging,Station,____________________________________________,38!

A.(Appendix( _________________________________________________________________(41!

Wall,Mount,Bracket,Dimension,________________________________________________,41!

Pedestal,mount,dimensions,(Front$view),________________________________________,42!

Bollard,mount,dimensions,(Side$view),__________________________________________,43!

Chapter 2.Pedestal Mount

7 | Page

Chapter(1.Introduction(

This document provides instructions for installing the ChargePro™ 620 Charging Station.

The ChargePro™ 620 Charging Station is shipped in two boxes.

! Box-1 – ChargePro™ 620 Charging Station Head Unit, Cable Rack and Cable Rack

screws

! Box-2 –

o If Pedestal Mount Configuration: Pedestal Unit, Anchor Plate and fasteners

o If Wall/Pole Mount Configuration: Wall/Pole Mount Bracket, Mounting

Template and fasteners

-.&/0*,+#%%#+0'*!1.&1#.#+0'*!

This guide assumes that the appropriate wiring, conduit and circuit protection is in place at the

installation site.

CHARGE PRO™ 620

CHARGING STATION

CHARGE PRO™ 620

MOUNTING ACCESSORIES

Charging Station Installation Guide

To assist in the process of preparing the installation site, carefully review the following:

! Wiring color code (Page 8)

! ChargePro™ 620 Charging Station technical specifications (Page 9)

! Wiring diagrams (Page 10)

! Wall/Pole Mounting Template (included in shipping container)

! Pedestal Unit Dimensions (Page 42 - 43)

Before installing the ChargePro™ 620 Charging Station, please review this entire document to

understand the required installation steps prior to beginning the process.

20.0*3!4'%'.!4'5&!

The illustrations and diagrams in this document reflect the Level-2 wiring color code. For Level-

1 wiring substitute the red wire with the white wire.

Strictly adhere to the wire color codes to ensure proper installation.

6&7&%/8!)9#.30*3!:+#+0'*!;8<=>?@!

Use 12 AWG wire minimum (10 AWG preferred) (ensure compliance with electrical codes).

COLOR CODE

BLACK

WHITE

GREEN

SERVICE

PHASE (L)

NEUTRAL

GROUND

6&7&%/<!)9#.30*3!:+#+0'*!;<A=>!'.!<=B>?@!

Use 10 AWG wire minimum (ensure compliance with electrical codes).

COLOR CODE

BLACK

RED

GREEN

SERVICE

PHASE A (L1)

PHASE B (L2)

GROUND

Chapter 2.Pedestal Mount

9 | Page

:1&40(04#+0'*,!

Power

Specs

AC Power Source

208/240V, center grounded, 60Hz supply

3-wire; Phase A, Phase B, ground (no neutral)

Power to Electric Vehicle

30A maximum, 7.2kW@240VAC

Branch Circuit Protector

2-pole, common trip, circuit breaker

Breaker rating125% of load (40A for 30A load)

Vehicle-to-Charger Connection

SAEJ1772 EV Connector via 18 ft Cable (supplied)

Energy Metering Accuracy

1% at 5 min intervals, 0.5% accuracy (optional)

Time-of-Use Metering

Charger support provided

Standby Power

typical

Safety

Specs

Personnel Protection System

Charging Circuit Interrupting Device (CCID)

Trip Threshold 5 mA, CCID5 per UL2231-2

Automatic³Unplug´Detection

Charger output voltage

terminated

Remote notification via SMS or email(owner configured)

Codes and Standards Compliance

Listed to UL2231-1,-2 and UL2594

NEC Article 625 compliant

Network

Specs

Local Area Network

2.4GHz 802.15.4 dynamic mesh network

Wide Area Network

Commercial CDMA or GPRS cellular network

Network Communication Protocol

TCP/IP

Network Security

HTTPS;128-bit AES Encryption

Maximum Charging Station per LAN

128

Smart Card Reader

ISO15693 compliant

Charger Status Indicating

Displays

LED Array

270 deg visibility, multi-color visual status indication

LCD Screen

2 lines, 16 characters per line, backlit

Environmental

Specs

Outdoor Rated

NEMA 3 per NEMA 250-1997, IP44 per IEC 60529

Operating H

umidity

Upto 95% non-condensing

Operating Temperature

-30 deg C to +50 deg C ambient

Other S

pecs

Surge Protection

6kV@3,000A per UL 2231-2,Extraprotection optional

EMI Compliance

FCC Part15 Class A

Dimensions

18in high x 6 in wide x 6 in deep

Charging Station Installation Guide

20.0*3!C*('.D#+0'*!

Chapter 2.Pedestal Mount

11 | Page

)9#1+&.!<E-&5&,+#%!F'G*+!

This chapter covers the installation of the ChargePro™ 620

Charging Station using a Pedestal Unit.

F#*G(#4+G.&.!:G11%0&5!F#+&.0#%,!('.!C*,+#%%#+0'*!

! The following items can be found in Box- 1

o ChargePro™ 620 Charging Station Head Unit

o Cable Rack and Cable Rack mounting screws (4ea)

! The following items can be found in Box- 2

o ChargePro™ 620 Charging Station Pedestal Unit

o Charging Station Anchor Plate

o Anchor Bolts

o Tamper- resistant screwdriver

C*,+#%%#+0'*!H7&.70&I!!

1. Check the boxes for correct content

2. Install the Anchor Plate

3. Install the Pedestal Unit

4. Attach the Cable Rack

5. Install the Charging Station Head Unit

The steps are further detailed in the remainder of this chapter.

Charging Station Installation Guide

:+&1!8!/!)9&4J!$'K&,!('.!4'..&4+!4'*+&*+!

The ChargePro™ 620 Charging Station shipping boxes contain:

Box-1 - Charging Station

! ChargePro™ 620 Charging Station Head Unit

! Cable Rack

! Cable Rack mounting screws (4ea)

Chapter 2.Pedestal Mount

13 | Page

Box-2 – Mounting Accessories

! ChargePro™ 620 Charging Station Pedestal Unit

! Head Unit mounting screws (4ea) with tamper-resistant screwdriver

! Pedestal Unit anchor bolts (4ea)

! Anchor Plate

Charging Station Installation Guide

:+&1!<!L!C*,+#%%!M*49'.!-%#+&!

:0+&!:&%&4+0'*!

Select the location for the charging station. To mount the

charging station, first prepare a concrete pad such that it is

properly aligned to the parking space.

The concrete pad should be positioned such the distance

between the charging station and electric vehicle is sufficient to

minimize likelihood of damage (suggested min. 3 ft).

:0+&!-.&1#.#+0'*!

The Anchor Plate is 18 inches in height; therefore it is

recommended that the concrete pad is at least 24 inches in

depth (check local codes).

In preparation for the concrete pad, excavate to a depth of

24 inches, length 18 inches (recommended), width 18

inches (recommended). Trench for electrical conduit into

this hole (check local codes).

Prepare the Anchor Plate

To prepare the Anchor Plate for installation, run

conduit through the anchor as illustrated in the

diagram. The conduit should run either through

the side hole in the Anchor Plate post or through

the bottom of the post itself. The conduit should

extend 2.5ft above the anchor plate (check local

codes).

Chapter 2.Pedestal Mount

15 | Page

Next, pass wires through the conduit such that the free end of the wires extends at least 12 inches

from the opening, giving enough slack to facilitate the connection to the device.

Also, note the alternative conduit path.

Pour concrete to fill the hole as shown above in the diagram. As the concrete fills up, with the

help of a Level, ensure that the base plate is parallel to the ground.

Allow sufficient time for the concrete to harden before going to the next step.

Charging Station Installation Guide

:+&1!N!/!C*,+#%%!-&5&,+#%!O*0+!

C*,&.+!+9&!-&5&,+#%!

Now we are ready to install the Pedestal Unit. Carefully place

the Pedestal Unit over the conduit and wires as illustrated in

the diagram.

Place the Pedestal Unit on the Anchor Plate such that the bolt

holes are aligned.

Ensure that the electric wires can be easily accessed through

the access window provided in the Pedestal’s top section.

M*49'.!$'%+,!P!6&7&%0*3!,4.&I,!

First insert anchor bolts and secure with one or two turns, but

do not tighten.

Note: The leveling screws that can be

found on four sides are used to adjust

for plumb.

Chapter 2.Pedestal Mount

17 | Page

Q*,G.&!-&5&,+#%!0,!-%GD$!

Adjust leveling screws to make pedestal plumb (check with

Level at two points separated by 90 degrees).

Tighten the #*49'. bolts

Gradually tighten anchor bolts to secure the Pedestal Unit

to the Anchor Plate. Re-check for plumb.

:+&1!A!L!M++#49!)#$%&!R#4J!

Attach the Cable Rack to the underside of the Charging

Station Head Unit (see diagram) using the four (4) Cable

Rack screws. After tightening screws, check that the Cable

Rack is secure and is firmly attached to the Head Unit.

Cable

Rack

Level

Charging Station Installation Guide

Access Panel

Tamper-

resistant

Screws

:+&1!S!L!C*,+#%%!+9&!)9#.30*3!:+#+0'*!T&#5!O*0+!

Next install the ChargePro™ 620 Charging Station Head Unit onto the

Pedestal.

F'G*+!+9&!49#.30*3!,+#+0'*!9&#5!G*0+!

Carefully insert the charging station head unit on top of the

pedestal as shown in the illustration. The access panel cut-outs

on the Pedestal Unit and Head Unit should be aligned.

U0.D%V!(#,+&*!+9&!49#.30*3!,+#+0'*!

As illustrated, attach the Charging Station Head Unit to the

Pedestal Unit with the four tamper-resistant screws provided

(two on each side). Ensure the charging station is plumb using

a level. Check that the Head Unit is now securely fastened to

the Pedestal.

Chapter 2.Pedestal Mount

19 | Page

)'**&4+0*3!+9&!I0.&,!

Open the Access Panel by removing the four screws. Locate and access the wires inside.

Carefully pull these wires a few inches outside of the access panel, to reveal 3 wires coming

from the Charging Station Head Unit (for Level-2 charging stations the color codes are Red,

Black and Green) and 3 wires from the Pedestal with the same color combination. Remove the

insulation on each wire and prepare to connect those using wire-nuts.

Match the wires using the colors (Black-Black, Green-Green & Red-Red) and connect them

using wire nuts as illustrated above. Once connected, slowly insert the wires into the device and

replace the access panel cover using the screws previously removed.

Caution: Refer to the wire color codes (Page 8) and strictly adhere to this convention while

connecting the charging station and electrical supply wires. Incorrect wiring can lead to an

electrical hazard.

-'I&.!O1!

Congratulations!

You have now finished the installation of the ChargePro™

620 Charging Station! You can now power up the device.

Charging Station Installation Guide

21 | Page

)9#1+&.NE2#%%!F'G*+!

This chapter covers the installation of the ChargePro™ 620 Charging Station on a wall.

F#*G(#4+G.&.!:G11%0&5!F#+&.0#%,!('.!C*,+#%%#+0'*!

! The following items can be found in Box-1

o ChargePro™ 620 Charging Station Head Unit

o Cable Rack and Cable Rack mounting screws

! The following items can be found in Box-2

o Wall/Pole Mount Bracket Plate

o Wall/Pole Mount Bracket Post

o Tamper-resistant screwdriver

o Wall Mount Template

C*,+#%%#+0'*!H7&.70&I!!

1. Check the boxes for correct content

2. Pre-installation preparation

3. Install Wall/Pole Mount Bracket

4. Attach the Cable Rack

5. Install the Charging Station Head Unit

The steps are further detailed in the remainder of this chapter.

Charging Station Installation Guide

:+&1!8!/!)9&4J!$'K&,!('.!4'..&4+!4'*+&*+!

The ChargePro™ 620 Charging Station boxes contain:

Box-1 - Charging Station Head Unit

! ChargePro™ 620 Charging Station Head Unit

! Cable Rack

! Cable Rack mounting screws (4ea)

23 | Page

Box-2 – Mounting Accessories

! ChargePro™ 620 Charging Station Wall/Pole Mount Bracket Plate

! Wall/Pole Mount Bracket anchor bolts (4ea)

! Wall/Pole Mount Bracket Post screws (3ea)

Charging Station Installation Guide

! Wall/Pole Mount Bracket Post

! Head Unit mounting screws (4ea) with tamper-resistant screwdriver

! Wall Mount Template

25 | Page

:+&1!<!L!-.&/0*,+#%%#+0'*!1.&1#.#+0'*!

:0+&!,&%&4+0'*!

The charging station should be positioned such the

distance between the charging station and electric vehicle

is sufficient to minimize likelihood of damage (suggested

min. 3 ft).Two alternatives are illustrated here.

-.&1#.0*3!+9&!I#%%!

At the selected location, place the wall-mount template on the

wall such that the top of the template is at a height of 49 inches

(Check local codes). The equipment should be installed at least

18 inches above the floor.

With the help of a Level, ensure the template is in an upright

position. Mark locations for the bolt locations. If running wire

inside wall also mark Wire Wall Hole.

Charging Station Installation Guide

If solid concrete or brick wall, drill ½ inch diameter holes to a depth of 4 inches for the anchor

bolts provided. For walls other than concrete, solid block or brick, use fasteners appropriate for

material.

Now, run conduit up to wire wall hole location previously marked on the wall. Run the wires

through this conduit up to wire wall hole location with at least 18” (+wall thickness) free wire.

See illustration for clarity.

NOTE: If the conduit is run on the same side of the wall as the charging station the wires are

then run through the opening on the side of the Wall/Pole Mount Bracket Post.

27 | Page

:+&1!N!/!C*,+#%%!+9&!2#%%W-'%&!F'G*+!X.#4J&+!

-.&1#.&!+9&!2#%%W-'%&!F'G*+!X.#4J&+!

First, prepare the wall bracket to be bolted on to the wall.

Firmly attach the Wall/Pole Mount Bracket Plate to the

Wall/Pole Mount Bracket Post using the Wall/Pole Mount

Post screws (3ea). Make sure that the Post is securely

attached to the Wall Mount Plate.

F'G*+!X.#4J&+!'*!+9&!$'%+,!

Now hang the Wall/Pole Mount Bracket on the anchor

bolts embedded in the wall, while carefully running the

wires through the Post. Ensure the wires run all the way to

the access panel opening.

Finish attaching bracket by securing nuts on bolts with

washers.

! !

Access Panel

& Wires

Charging Station Installation Guide

:+&1!A!L!M++#49!)#$%&!R#4J!

Attach the cable rack to the underside of the charging station as illustrated, using the four

(4) cable rack screws. Ensure the rack has been attached properly and can carry the

weight of the cable that will be placed on the it.

Cable Rack

29 | Page

:+&1!S!L!C*,+#%%!+9&!)9#.30*3!:+#+0'*!T&#5!O*0+!

Now we are ready to install the charging station.

F'G*+!+9&!49#.30*3!,+#+0'*!

Carefully insert the Charging Station Head Unit on top of the

Wall Mount Bracket Post as shown in the diagram. The access

panel on the Charging Station Head Unit should be aligned with

the panel on the Wall/Pole Mount Bracket Post.

U0.D%V!(#,+&*!+9&!49#.30*3!,+#+0'*!

Attach the Charging Station Head Unit to the Post using the

four (4) tamper-resistant screws provided (two on each side).

Ensure the charging station is plumb using a Level. Check that

the Head Unit is now securely fastened to the Post.

Tamper-

resistant

Screws

Access

Panel

Charging Station Installation Guide

)'**&4+0*3!+9&!I0.&,!

Open the Access Panel by removing the four (4) screws. Locate and access the wires inside.