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GE NEMA User's Manual & Installation Instructions

Evse charging station
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EV Charging Station
User Manual & Installation Instructions
NEMA EVSE CHARGING STATION
USER MANUAL & INSTALLATION INSTRUCTIONS
POLE-MOUNT
WALL-MOUNT
PEDESTAL
BACK TO BACK
GE EV Charging Station User Manual
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  • Page 1 EV Charging Station User Manual & Installation Instructions NEMA EVSE CHARGING STATION USER MANUAL & INSTALLATION INSTRUCTIONS POLE-MOUNT WALL-MOUNT PEDESTAL BACK TO BACK GE EV Charging Station User Manual 1 of 86...

  • Page 2: Table Of Contents

    4.4.3 Install EV100 RFID Host Application Software........................79 4.4.4 Setup Validation....................................80 Setup without RFID Authentication ............................82 Reset Controller to Factory Default ............................83 Trouble Shooting Guide ................................... 84 GE EV Charging Station User Manual 2 of 86...

  • Page 3: Important Safety And Grounding Instructions

    This should be run with circuit conductors and connected to the equipment grounding bar or lead on the EVSE. Connections to the EVSE shall comply with all applicable electrical codes and ordinances. GE EV Charging Station User Manual 3 of 86...

  • Page 4: Installation Instruction

    GROUND TERM. SCREWS, 14-10 AWG 34 in-lb +/- 5 in-lb GROUND TERM. SCREWS, 8 AWG 38 in-lb +/- 5 in-lb 3/4" LOCKNUT HAND TIGHT + 1/4 TURN - Table 1 - GE EV Charging Station User Manual 4 of 86...

  • Page 5: Pedestal

    Bill of materials ITEM DESCRIPTION Kiosk Pedestal Unit Base Mounting Assembly Kiosk Skirting Base Mounting Template, NEMA 3R Hex Nut, ½” SS Star Washer, External Tooth, ½” SS - Table 3 - GE EV Charging Station User Manual 5 of 86...
  • Page 6 EV Charging Station User Manual & Installation Instructions Procedure Item 1 Item 5 & 6 Item 3 Item 4 Item 2 Figure 1: Exploded pedestal base assembly GE EV Charging Station User Manual 6 of 86...
  • Page 7 Route power conduit and communication conduit through the center of the hole in the mounting template, appropriately. Install base mounting assembly plate securely over conduits with mounting template and four 1/2-13 nuts. GE EV Charging Station User Manual 7 of 86...
  • Page 8 Pour concrete to level shown in Figure 4. Do not cover the ½-13 nuts with concrete. Remove mounting template from threaded rods, after concrete has cured. Do not remove the ½-13 nuts as they are used for leveling the skirt. GE EV Charging Station User Manual 8 of 86...
  • Page 9 Install ½-13 nuts and star washers after lowering skirt over matching threaded rods over the ½-13 nuts. Use the bottom ½-13 nuts for leveling the skirt. Fasten nuts and skirt assembly to concrete base, as shown in Figure 5. Torque nuts per specification Table 1 GE EV Charging Station User Manual 9 of 86...
  • Page 10 Connections to the EVSE shall comply with all applicable electrical codes and ordinances. In case of RFID sensor, the communication cable is connected to the Ethernet connector on the controller as shown in Figure 9. GE EV Charging Station User Manual 10 of 86...
  • Page 11 Incoming Power Fuse Block Incoming Power Cables Connect at Bottom Terminals of Fuse Block Ground Wire Connects to Ground Bars Figure 8 : Power Wire and Ground Wire Connections for Pedestal GE EV Charging Station User Manual 11 of 86...

  • Page 12: Double Pedestal (Back To Back)

    Bill of materials ITEM DESCRIPTION Kiosk Pedestal Unit Base Mounting Assembly Kiosk Skirting Base Mounting Template, NEMA 3R Hex Nut, ½” SS Star Washer, External Tooth, ½” SS - Table 4 - GE EV Charging Station User Manual 12 of 86...
  • Page 13 EV Charging Station User Manual & Installation Instructions Procedure Item 1 Item 5 & 6 Item 3 Item 4 Item 2 Figure 10: Exploded double pedestal base assembly GE EV Charging Station User Manual 13 of 86...
  • Page 14 Route power conduit and communication conduit through the center of the hole in the mounting template, appropriately. Install base mounting assembly plate securely over conduits with mounting template and four 1/2-13 nuts. GE EV Charging Station User Manual 14 of 86...
  • Page 15 Pour concrete to level shown in Figure 13. Do not cover the ½-13 nuts with concrete. Remove mounting template from threaded rods after concrete has cured. Do not remove ½-13 nuts as they are used for leveling the skirt. GE EV Charging Station User Manual 15 of 86...
  • Page 16 Install ½-13 nuts and star washers after lowering skirt over matching threaded rods over the ½-13 nuts. Use the bottom ½-13 nuts for leveling the skirt. Fasten nuts and skirt assembly to concrete base, as shown in Figure 14. Torque nuts per specification Table 1. GE EV Charging Station User Manual 16 of 86...
  • Page 17 Connections to the EVSE shall comply with all applicable electrical codes and ordinances. In case of RFID sensor, the communication cable is connected to the Ethernet connector on controller 1 and 2 as shown in Figure 18. GE EV Charging Station User Manual 17 of 86...
  • Page 18 Ground Bar 1 Incoming Power Cables Connect at Bottom Terminals of Fuse Blocks Ground Wires Connect to Ground Bars Figure 17 : Power Wire and Ground Wire Connections for Double Pedestal GE EV Charging Station User Manual 18 of 86...

  • Page 19: Wall-Mounted

    Drill 6 holes in the wall as illustrated in Figure 19. Use the supplied wall-mounting bracket to ensure correct alignment. The height of the bottom hole from the floor should be between 19” to 25” to GE EV Charging Station User Manual 19 of 86...
  • Page 20 ¾” conduit hubs to conduits. If the communication cable and the corresponding conduit is not used, cover the hole with supplied NEMA 3R knockout plugs. Optionally, the power wire can be run through the bottom of the enclosure. See page 24.
  • Page 21 EV Charging Station User Manual & Installation Instructions MIN: 18” MAX: 24” Figure 21: Wall Mount Installation, Critical Dimension GE EV Charging Station User Manual 21 of 86...
  • Page 22 Stud Wall Pre-drill hole dia. 3/8" Hardwood (into wood stud) Pre-drill hole dia. 1/4" Softwood Hollow Wall Anchor Cobra Anchors TripleGrip Drywall Pre-drill hole dia. 3/8" (into sheetrock) - Table 6 – GE EV Charging Station User Manual 22 of 86...
  • Page 23 ¼-20 HEX NUT, ¼: SEALING WASHER ¾” CONDUIT HUB Figure 22: Wall-Mount Installation, Exploded View Connect L1, L2 to the fuse block and ground wire to the ground bar shown in Figure 23. GE EV Charging Station User Manual 23 of 86...
  • Page 24 If this option is preferred, remove the two knockouts at the bottom of the enclosure and fill in the unused cable holes on the back of the enclosure using the spare NEMA 3R knockout plugs provided. See Figure 24. Assemble the supplied conduit hub in the bottom and make the conduit arrangement.

  • Page 25: Pole-Mounted

    Attach to ¾” conduits/enclosure Conduit Nipple ¾” pipe size, 1.05”OD, NPTXNPT (Installer supplied) threaded both ends Nipple. Example: Metallic - McMaster Carr part 7727K225 or similar suitable plastic conduit nipple - Table 7 - GE EV Charging Station User Manual 25 of 86...
  • Page 26 NEMA 3R knockout plug and do not drill the corresponding hole in the pole. The height of the holes from the floor should be from 20” to 25” as shown in Figure 25 to meet UL and American Disability Act compliance.
  • Page 27 Strap the pole bracket assembly to the pole by supplied ¾” by 0.030” stainless steel banding as shown in the Figure 27. IMPORTANT: You must use a high tension-banding tool to install bands. (GE Part no: EVPMBAND) GE EV Charging Station User Manual 27 of 86...
  • Page 28 Install the Kiosk pole mounted unit, using the nuts and sealing washers as shown in Figure 28. Torque all the nuts as per the torque specification in Table 1. GE EV Charging Station User Manual 28 of 86...
  • Page 29 If this option is preferred, remove the two knockouts at the bottom of the enclosure and fill in the unused cable holes on the back of the enclosure using the spare NEMA 3R knockout plugs provided. See Figure 30. Assemble the supplied conduit hub in the bottom and make the conduit arrangement.
  • Page 30 EV Charging Station User Manual & Installation Instructions CONDUIT HUB PLUG Figure 29: Pole-Mount Conduit Using Side Fittings Figure 30: Alternate Pole-Mount Conduit Installation Using Installations Bottom Knockouts GE EV Charging Station User Manual 30 of 86...

  • Page 31: Accessory Kits

    EV100CD CD with standalone SW EV100 EVRCW50 Pack of 10 white RIFD cards EVRCG50 Pack of 10 GE US RFID cards EVPMBAND Pole mount strap installation kit - Table 8 - 2.9 Replacement Kits The EV Charging Station offers the following replacement kits:...
  • Page 32 (EVDSDR01 and EVDSDR02). Instructions for the installation of these kits are provided in the following sections. The remaining kits should be installed by a trained GE technician. GE EV Charging Station User Manual 32 of 86...

  • Page 33: Rfid

    2.9.1 RFID This section describes how to install the RFID hardware for Pedestal, Wall Mounted and Pole Mounted EVSE units only. For the Back to Back EVSE unit RFID upgrade, contact a GE representative by calling 1-800-GE1STOP. WARNING: Make sure power to the EVSE is...
  • Page 34 Next, attach the RFID mounting plate to the outside of the EVSE enclosure as shown in Figure 33 and 34, using the hardware provided with RFID. Figure 33: RFID mounting plate, outside view GE EV Charging Station User Manual 34 of 86...
  • Page 35 Slide the RFID cable through the open hole as shown in Figure 35, and attach the RFID to its mounting plate as shown in Figure 36 using the tamper-proof screw provided. Figure 35: RFID cable GE EV Charging Station User Manual 35 of 86...
  • Page 36 Slide the threaded gland and seal over the RFID cable from the inside of the enclosure and screw it into the threaded hole. Then slide the RFID gland nut over the cable and screw it over the seal and threaded gland. Refer to Figure 37 and 38 below. GE EV Charging Station User Manual 36 of 86...
  • Page 37 EV Charging Station User Manual & Installation Instructions Figure 37: RFID gland assembly Figure 38: RFID gland assembly GE EV Charging Station User Manual 37 of 86...
  • Page 38 Figure 40: RFID wiring Attach the Phoenix connector to the controller in its designated location, as shown in Figure 41 and 42. Make sure to press the Phoenix collector fully into the female socket. GE EV Charging Station User Manual 38 of 86...
  • Page 39 EV Charging Station User Manual & Installation Instructions Figure 41: RFID Connection Location Figure 42: RFID Connection Location GE EV Charging Station User Manual 39 of 86...

  • Page 40: Vfd

    This section describes how to install the VFD for Pedestal, Wall Mounted and Pole Mounted EVSE units only. For the Back to Back EVSE unit VFD replacement, contact a GE representative by calling 1- 800-GE1STOP.
  • Page 41 Remove the RFID unit (or the metal plate and gasket if no RFID has been provided) from the VFID mounting assembly as described in Section 2.9.1. Install the new VFD/RFID mounting assembly, shown in Figure 45 and Figure 46. GE EV Charging Station User Manual 41 of 86...

  • Page 42: Holding Socket

    This section describes how to install the holding socket for Pedestal, Wall Mounted and Pole Mounted EVSE units only. For the Back to Back EVSE unit holding socket replacement, contact a GE representative by calling 1-800-GE1STOP.
  • Page 43 Figure 47: Holding Socket Phoenix Connection Remove the holding socket by unscrewing the four tamper-proof placement screws on the front face of the EVSE enclosure, shown in Figure 48. Figure 48: Holding Socket Tamper-Proof Screws GE EV Charging Station User Manual 43 of 86...

  • Page 44: Service Door

    Remove the door ground wire from door ground stud, shown in Figure 49. Figure 49: Door Ground Connection Insert the new door and replace the ground wire to the door ground stud. GE EV Charging Station User Manual 44 of 86...

  • Page 45: Wiring Diagram

    EV Charging Station User Manual & Installation Instructions 2.10 Wiring Diagram The wiring diagram shown in Figure 50 is applicable for all NEMA EVSE units and is included as a reference. Figure 50: EVSE Wiring Diagram GE EV Charging Station User Manual...

  • Page 46: User Manual

    While unpacking, examine the product for broken, bent, or loose parts or other damage. If damage from shipment is evident, file a damage claim with the transportation company and notify the nearest sales office. GE EV Charging Station User Manual 46 of 86...

  • Page 47: Basic User Instructions

    Green (SOLID): EVSE available for charging  BLINKING Green: EV connected, but not energized (charging is finished or vehicle not ready for charging)  Amber (SOLID): EV charging and connector energized  Red (SOLID): Fault EVSE GE EV Charging Station User Manual 47 of 86...
  • Page 48 When the RFID is idle, the RFID LED is red. Figure 52: EVSE while idle When the access card is waved in from of the RFID reader, it blinks green and beeps for 250 ms. See Figure 53 below. GE EV Charging Station User Manual 48 of 86...
  • Page 49 EVSE is SOLID GREEN. The VFD should prompt the user to remove plug from socket and connect to vehicle. If the EVSE is displaying RED, then do not use the EVSE and contact GE technical support for assistance.
  • Page 50 (status indicator is GREEN or FLASHING GREEN), the EVSE will lockout and the status indicator will indicate RED. The lockout will prevent any vehicle from being charged until power has been cycled on the EVSE. Self-Test Fault: GE EV Charging Station User Manual 50 of 86...

  • Page 51: Technical Data

    EVSE fuse, charging will be interrupted and the status indicator will show turn RED. This fault can be cleared by disconnecting from the EV. 3.3 Technical Data The GE EV Charging Station has features which provide a robust and reliable solution for the needs of EV charging infrastructure.  LED light to display charger status ...
  • Page 52 Random start up between 0 and 15 minutes Local Area Network CAT5 Ethernet Network Communication Protocol TCP/IP Network Security GE recommends that network be VPN and Firewall protected Metering Accuracy 2% accurate on voltage and current; 4% accurate on power and energy RFID Reader ISO15693 compliant...

  • Page 53: Additional Considerations

    And all conduits should firmly attach to the secured “box” where communications would be terminated within the Charging Station. 3.5 EVSE Controller Settings 3.5.1 Configuration Switch Settings Using the configuration dip-switch S6, the controller can be placed into the desired operational mode. GE EV Charging Station User Manual 53 of 86...
  • Page 54 The configuration dip switch has positions 1 thru 8. Switches 1 to 4 are set and locked by the manufacturer, and switch 5 is reserved for future use. Switches 6, 7 and 8 are set at installation of the EVSE into its operational environment. GE EV Charging Station User Manual 54 of 86...

  • Page 55: Display Fault Messages

    Fault indicating that the controller has experienced the maximum allowed number of ground faults for a charge cycle.. To reset this fault simply disconnect the EVSE plug from the vehicle, and wait for at least 30 seconds. GE EV Charging Station User Manual 55 of 86...
  • Page 56 Indicates an incorrect hardware configuration. Ensure that the controller is placed in the correct desired configuration using the Dip Switch (S6) and properly installed into the system. This fault can only be cleared by cycling power to the EVSE. GE EV Charging Station User Manual 56 of 86...
  • Page 57 To clear and reattempt to read the MAC address, power to the EVSE must be removed and reapplied. Repeated occurrence of this fault indicates need for a replacement control board. GE EV Charging Station User Manual 57 of 86...

  • Page 58: Network Setup Instructions

    CS: Charging Station. These are individual units that provide electrical charging services to vehicle at a time. (Double pedestal provides charging to two) o Host System/Host PC: The PC that runs the GE EV Charging Station Manager Application to manage authorization and collect data from the Charging Stations.

  • Page 59: Controller Configuration

    Checkpoint, SonicWall, etc) and provide a true DMZ capability. Typical SOHO firewalls do NOT provide true DMZ capabilities. GE supports the use of the Cisco ASA5505 firewall and provides settings for its use in this scenario. o Physical Security. Physical security is a necessary consideration in any installation of this type. There should be physical controls to reduce the probability of a malicious entity’s chances of gaining access to any...
  • Page 60 (TCP/IP). Select this protocol by clicking on it and then click on the Properties button to open the window that will allow you to set the IP address and Subnet mask. Figure 58: TCP/IP settings on the test PC GE EV Charging Station User Manual 60 of 86...

  • Page 61: Evse Configuration Server Interface

    1. Switch off EVSE main Circuit Breaker (Removing power from the EVSE). Connect the Ethernet test cable to the EVSE controller Ethernet port J1 and the other end to the service laptop Ethernet connector. GE EV Charging Station User Manual 61 of 86...
  • Page 62 2. It is recommended to use a crossed Ethernet cable for direct connectivity between the EVSE and the service laptop or PC. S6 - Configuration Dip Switch Ethernet Connector J1 Figure 60: EVSE Controller GE EV Charging Station User Manual 62 of 86...
  • Page 63 Note: Should the EVSE in question previously have been assigned a different default EVSE IP address, enter here that IP address. Note: If you have forgotten the IP address of this EVSE, reset the controller. GE EV Charging Station User Manual 63 of 86...
  • Page 64 EV Charging Station User Manual & Installation Instructions 7. The Controller will invoke the following page: Figure 62: Configuration Server Entry Screen 8. Pressing the Enter Configuration button, the following page will load: GE EV Charging Station User Manual 64 of 86...
  • Page 65 Note: The default values normally need not be changed if the EVSE in question is used in a non- RFID authentication mode. Figure 63: Configuration server page with factory default values GE EV Charging Station User Manual 65 of 86...
  • Page 66 11. Change the position of the S6 Dip-switch back to:  Switch 8- Closed (Normal operation) Keep the other switches in their previous positions. This Dip-Switch configuration will enable the normal operation of the EVSE controller after powered GE EV Charging Station User Manual 66 of 86...

  • Page 67: Recommended Network Designs For Rfid Authentication

     Optional Modem (for remote service only, otherwise not required)  Card reader, accessory from GE catalogue # EVRP01 (Note: only GE enrollment readers work with this application) EVSE Controller Settings Follow the instructions in the Controller Configuration section to set up each individual EVSE...
  • Page 68 If there is a large number of EVSE on a local feed, consider setting this box to enable a gradual increase in load on resumption of power. Require Authorization for charging.  RFID authentication requires this check box to be checked on all EVSE in the network. Action required ! GE EV Charging Station User Manual 68 of 86...
  • Page 69 EVSE a unique ID. required ! IDs will appear in the EV100 Application in the format “1-12-9” (e.g. Locality ID = 1, Facility ID = 12, Unit number = 9). GE EV Charging Station User Manual 69 of 86...
  • Page 70 Then follow these steps to configure your TCP/IP settings for communication with the EVSE during setup. The NIC on the host PC should be connected to the Charging Station Network Ethernet Switch. GE EV Charging Station User Manual 70 of 86...
  • Page 71 Scroll through the protocols used by the local area connection to find the Internet Protocol (TCP/IP). Select this protocol by clicking on it and then click on the Properties button to open the window that will allow you to set the IP address and Subnet mask. GE EV Charging Station User Manual 71 of 86...
  • Page 72 Note: The IP address above must match the Host IP address entered in the configuration page of all connected EVSE. By default, this is 192.168.2.19. Note: Reboot PC to finalize with the configuration. GE EV Charging Station User Manual 72 of 86...

  • Page 73: Option 2: Charging Station Network Isolated From Customer Network With Host System In A Dmz

     Cat 5 Network Cables  Ethernet Switch  ASA5505 security plus firewall  Card reader, accessory from GE catalogue # EVRP01 (Note: only GE enrollment readers work with this application) GE EV Charging Station User Manual 73 of 86...
  • Page 74 Note: It is recommended to keep track of the different IP settings for each EVSE by recording them on the form found on the final page of this document. Subnet Mask  See above GE EV Charging Station User Manual 74 of 86...
  • Page 75 Change the value to 9500 for both the Host and Source Port to match the default value fo the Action EV100 Application SW. Unless there is a collision by using this Port on the host PC, it is required ! GE EV Charging Station User Manual 75 of 86...
  • Page 76 ID not previously used on this network to avoid transaction data to be lost. After the desired settings were configured click on “Save”. Repeat this procedure for all EVSE in the network. GE EV Charging Station User Manual 76 of 86...
  • Page 77 0/0 on the firewall to port 1 on the Charging Station Network Ethernet Switch. To configure the network settings on a PC running Windows XP Press the Start button and open the Control Panel. Select the Network Connections applet. Figure 72: Network Connections GE EV Charging Station User Manual 77 of 86...
  • Page 78 Figure 74: Network Settings Option 2 (See the Configuration Server Interface section) Click the Radio button to “Use the following IP Address” and then enter both the IP address and Subnet mask as shown. GE EV Charging Station User Manual 78 of 86...

  • Page 79: Install Ev100 Rfid Host Application Software

    After the controller configuration of all EVSE and the host PC’s TCP/IP setups have been completed, the Host Application EV100 for RFID authentication needs to be installed. GE strongly recommends using a clean PC with a fresh Windows XP or Windows 7 installation only, to avoid any interference with other installed software.

  • Page 80: Setup Validation

    Figure 75 4.4.4 Setup Validation After the successful installation of the EVSE network and EV100 Software, validate the installation by following these steps: 1. Check that the EV100 Listener Service is running GE EV Charging Station User Manual 80 of 86...
  • Page 81 In order to enroll new drivers, follow these steps or detail instructions included in the Help>Add driver section - Plug in the enrollment card reader (accessory from GE, cat # EVRP01) into the USB port - Wait for the USB driver installation to successfully complete - Click on “Add”...

  • Page 82: Setup Without Rfid Authentication

    Note: It is recommended to keep track of the different IP settings for each EVSE by recording them on the form found on the final page of this document. Figure 76: Factory Default values GE EV Charging Station User Manual 82 of 86...

  • Page 83: Reset Controller To Factory Default

    5. Remove short from connector J21. 6. Switch on EVSE main breaker to supply power to the controller., 7. Reconfigure as desired via EVSE controller configuration server interface. See description in an earlier chapter. GE EV Charging Station User Manual 83 of 86...

  • Page 84: Trouble Shooting Guide

    Station ID must be modified to a new ID not previously used on this network to avoid transaction data to be lost. 4.7 Trouble Shooting Guide For assistance with EVSE troubleshooting, please refer to the following website: www.geindustrial.com/evsupport GE EV Charging Station User Manual 84 of 86...
  • Page 85 EVSE Settings for ID __________________________________ Locality: ________________________________________________ Facility: _________________________________________________ Unit Number: ____________________________________________ Print one page for each EVSE and keep this record in a safe location or inside the corresponding EVSE. GE EV Charging Station User Manual 85 of 86...
  • Page 86 Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the GE company. GE Industrial Solutions 41 Woodford Ave.

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