Ford PRO Rev B AC Charging Station Installation Guide

Ford PRO Rev B AC Charging Station

INSTALLATION GUIDE

1. Introduction

1.1. Overview

This user manual applies to Ford Pro™ AC Charging Station 80A (Series 2). Any unauthorized modifications will void the product warranty.

Figure 1.1 Ford Pro™ AC Charging Station 80A (Series 2) Overview

Figure 1.2 Ford Pro™ AC Charging Station 80A (Series 2) Dimensions

1.2. Box Contents

Inside the box, you will find the following components.

Table 1.1 Box Contents

on front cover.
5| Accessory Bag| 1|

1.3. Product Specifications

Table 1.2 Product Specifications

panel, Brightness 600 cd/m2, LED back- light life min. 50,000 hours
Cloud Communica- tions| OCPP 1.6J
Authentication Method| RFID + ISO15118 capable
Operation Temp.| -40 ~ 50 °C (-40 to 122 °F)
Storage Temp.| -40 ~ 80 °C (-40 to 176 °F)
Maximum Operating Altitude| 3,500m above sea level
Meter Accuracy| ±1%
Mounting Type| Wall mount / Pole mount (optional)
Wiring Type| Hard-wired
Enclosure Level| NEMA 4
Impact Resistance| IK10
Dimension(H x W x D)| 14.2”x10.6”x5.8”
Web Portal Manage- ment| Yes
Console Management| Yes
Certification| UL 1998/2231/2594 FCC Part 15B
FCC Part 15.247 (WLAN 2.4GHz)
Energy Star
FCC Part 22/24/27

NOTE

Cellular is pre-configured on the charger. If cellular connection is not good, charger will default to Ethernet and then Wi-Fi.
If you need assistance with this, contact Ford Pro Charging.

2. Important Safety Instructions

This document contains instructions and warnings which must be followed when installing and using the Electric Vehicle Supply Equipment (EVSE). Before install-ing or using the EVSE, read this entire document as well as WARNING and CAU-TION markings in this document.

The symbols used have the following meaning:

WARNING: RISK OF PERSONAL INJURY
WARNING: RISK OF ELECTRIC SHOCK
WARNING: RISK OF FIRE OR EXPLOSION
CAUTION: RISK OF DAMAGE TO THE EQUIPMENT
NOTE: Information pertinent to procedure

• The information provided in this manual in no way exempts the user of responsibility to follow all applicable codes or safety standards.
• This document provides instructions for the Electric Vehicle Supply Equipment (EVSE) and should not be used for any other product.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Do not drag this equipment by input power cord.

2.1. Repair and Maintenance Clause

• Only licensed electricians can repair or maintain the charger. It is forbidden for general users to install, repair, or maintain it.
• Turn off input power and verify absence of voltage before installation, repair, &/or maintenance of the charge point.

2.2. Federal Communication Commission Interference State-ment

This equipment complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This equipment may not cause harmful interference, and (2) this equipment must accept any interference received, including interfer-ence that may cause undesired operation.

80A Charging Station Series 2

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential instal-lation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be deter-mined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is con-nected.
• Consult the dealer or an experienced radio/TV technician for help.

Changes or modifications not covered in this guide must be approved in writing by the manufacturer’s Regulatory Engineering Department. Changes or modifica- tions made without written approval may void the user’s authority to operate this equipment.

2.3. Industry Canada Statement:

This equipment complies with ISED’s license-exempt RSSs. Operation is subject to the following two conditions: (1) This device may not cause harmful interfer-ence, and (2) this equipment must accept any interference received, including interference that may cause undesired operation.

2.4. Radiation Exposure Statement:

This equipment complies with FCC / ISED radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with greater than 20 cm between the radiator & your body.

WARNING RISK OF PERSONAL INJURY

This equipment is intended only for charging vehicles that do not require ventilation during charging. Refer to your vehicle’s owner’s manual to determine ventilation requirements.

WARNING RISK OF PERSONAL INJURY

Do not use extender cables to increase the length of the charging cable.
Maximum length is limited to 25 feet by the National Fire Protection Agency.

WARNING RISK OF ELECTRIC SHOCK

Basic precautions should always be followed when using electrical products, including the following:

• Read all the instructions before using this equipment.
• This equipment should be supervised when used around children.
• Do not put fingers into the EV connector.
• Do not use this equipment if the flexible power cord or EV cable is frayed, has broken insulation, or shows any other signs of damage.
• Do not use this equipment if the enclosure or the EV connector is broken, cracked, open, or shows any other indication of damage.

WARNING RISK OF ELECTRIC SHOCK

Do not touch live electrical parts. Incorrect connections may cause electric shock.

WARNING RISK OF FIRE OR EXPLOSION

To reduce the risk of fire, replace only with same type and rating of fuse.

WARNING RISK OF FIRE OR EXPLOSION

This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors. It should not be located in a recessed area or below floor level. Automatic reset feature provided.

WARNING RISK OF FIRE OR EXPLOSION

Do not use this device with an extension cord.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Do not operate this equipment in temperatures outside its operating range of -40°C to +50°C (-40°F to +122°F).

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Store this equipment in a clean dry place in temperatures between -40°C and +80°C (-40°F to +176°F).

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Do not drag this equipment by input power cord.

SAVE THIS INSTRUCTION

2.5. Pre-Installation Safety Check

• Check for transport damages.
• Before connecting the product to the power supply, check the power supply voltage and current rating corresponds with the power supply details shown on the product rating label.

DANGER RISK OF SUFFOCATION

Keep any packing materials away from children – these materials are a potential source of danger, e.g. suffocation.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Disconnect the power supply before installing or repairing the charger.
Failure to do so may result in physical injury or damage to the power supply system and the charger.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Avoid touching or pressing the LCD screen, as this may result in damage to the LCD screen.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

Do not use extension cord sets.

The charger must be installed only by a licensed electrician in accordance with the provisions of the local electrical industry construction and should comply with National Electrical Codes and standards.
Before installing the charger, make sure you have read all of these instructions in this manual and fully understand its contents.

Appropriate protection is required when connecting to a main switchboard. The tools and parts used as outlined in the section “Tools & parts required for installa-tion”.

2.6. Grounding instructions

The charger must have equipment grounding through a permanent wiring system or an equipment grounding conductor. Use a wire with a dedicated grounding wire and a ring terminal and connect to the equipment ground terminal block for grounding.

2.7. Tools & Parts Required for Installation

Table 2.3 Tools & Parts Required for Installation

surface
Screw| 4| All| Tapping: #12| No| Fasten mounting bracket
| 1| All| Mechanical: M6| Yes| Fasten charger & mount bracket
Wire, Copper| 3| All| 2 x 2 AWG, 1
x 8 AWG (for ground wire)| No| Other wire sizes may be acceptable depending on site conditions and AHJ
Conduit| 1| All| 1 inch| No| Protect power cable
Torx Screwdriver| 1| All| Security Bit T20| No|
Hexagon Screw- driver| 1| All| 3/16| No| Tighten #12 tapping screws
Torque Wrench| 1| All| 40 kgf-cm min| No|
Amperage Reduc- tion Label| 1| All| 195*140 mm| Yes| A reminder to the field in- staller.

3. Unboxing

Procedure 1. Carton Opening Process

1. Open the carton and remove the upper plate

2. Take out the charger.

4. Charger Installation

Step 1. Disassemble top cover.

Step 2. Remove interior install cover.

Step 3. Remove the mounting bracket by sliding the bracket down and off

the charger.

Step 4. Secure the main body mounting bracket to the wall with appropriate screws.

Follow applicable accessibility requirements for the mounting position. The unit shall be stored or located at a sufficient height. For indoor site, it should be in-stalled between 18 inches (450 mm) and 4 feet (1.2m) above ground. For outdoor site, it should be installed between 24 inches (600 mm) and 4 feet (1.2m) above ground. Refer to Article 625, NEC.

The mounting bracket has ten screw holes. If only two screws be used to fasten the mounting bracket, the screws should pass through the middle two screw holes of the mounting bracket. The other screw holes are reserved for the user.

Screw sizing suggestion:

• For masonry walls, use M6 mechanical screws. (Commercially Available)
• For finished walls supported by wood studs, use #12 tapping screws.
• Refer to the following screw torque guide. The actual torque is according to the wall material.

Step 5. Fasten Charger onto Mounting Bracket

1. Put the charger on the mounting bracket.

2. Fasten charger on mounting bracket by tightening M6 screw.

3. Refer to the following screw torque guide.

Step 6. Stick the Amperage Reduction Label on the Charger

If you need to set your charger’s current lower than the max. rating, use the label corresponding to your selected current value from the amperage reduction label.

1. The rotary switch label sticker is on the installation cover.

2. Stick the product label over the main label to cover up the original In/Out information.

3. Stick the Amperage label on the breaker (optional).

4.1. Input Power Cord Installation

Step 7. Choose the appropriate conduit in accordance with all applicable state, local, and National Electrical Codes and standards.

Step 8. Connect the electrical wiring to the charger.

• Fold the wire ends to pass through the conduit and insert them into the input hole (choose input direction 1 – rear or 2 – bottom and open cap). Secure charger onto mounting bracket.

• For rear or bottom hole installation, use an appropriate conduit (1 inch conduit is recommended) which meets the NEMA 4 standard.

Refer to the following wire specification. Use a conductor type other than RHH, RHW and RGW-2 with outer covering. Choose the appropriate conductors in accordance with all applicable, state, local and national electric codes and standards.

The stripping length of the wire is recommended to be 15mm+/-0.5mm.

Step 9. Fasten the copper wire on the corresponding terminal block. The wiring instruction is printed in front of the terminal block (L1/L2/G).

Step 10. Use the following torque to connect the wire to the terminal block.

WARNING RISK OF FIRE OR EXPLOSION

To reduce the risk of fire, connect only to a circuit provided with the required branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70, and the Canadian Electrical Code, Part I, C22.2.

CAUTION RISK OF DAMAGE TO THE EQUIPMENT

If this unit is installed outdoors, the outlet must be rated for outdoor installation.

The outlet must be installed properly to maintain the proper NEMA rating of the enclosure.

See Section 4.2. Adjust Max. Output Current for details on charger derate settings.
Step 11. Lock the conduit on the enclosure. Refer to the following torque.

| Conduit| Torque|
---|---|---|---
| 1 “| 35 kgf·cm| 30.36 lbf·in|
Step 12.   Reassemble interior install cover and front cover then fasten M4 screw.
| Screw| Torque|
| M4| 15 kgf.cm| 13 lbf·in|

4.2. Adjust Max. Output Current

Step 13. Configure the rotary switch to set the Max. output current.

If the charger is installed on a circuit breaker smaller than 100A, the rotary switch should be adjusted to limit charger output to less than or equal to 80% of the circuit breakers rating. (Eg: For a 60A circuit breaker, the charger output limit should be adjusted to no more than 48A.) If needed, Amperage Reduction Labels are available to place on charger and circuit breaker.

WARNING RISK OF ELECTRIC SHOCK

Power must remain off before setting or configuring the rotary switch.

4.3. Ethernet Cable Installation

Ethernet can be used if there is no cellular or WIFI connection. Connect an ethernet cable to the charger through grommet.

NOTE

Do NOT remove the grommets. Instead, let Ethernet cable pass through the grommets.
Use tools to combine the RJ45 connector with RJ45 Cable. By using this method, the IP level could be ≥IP55. The Erthernet cable diameter should be 3.5mm – 5mm.

5. Operations

5.1. Charging Status Indicators

Table 5.1 Charging Status Indicators

5.2. RFID Access Control Management

RFID Access Control is an optional software feature on the chargers. Reach out to Ford Pro Charging fordpro.com for customer support options to Purchase RFID
Cards and to Add, Activate, & De-Activate RFID cards from Account or Assign/Associate
RFID cards to Charging Depot.

5.3. Troubleshooting Guide

Scan the QR Code for the associated troubleshooting errors

5.4. Charging an Electric Vehicle (EV)

Choices of start charging are as below:

5.4.1. Operation for Charger as Shipped (Plug and Charge)

1. Insert the charging plug into the EV
2. Charging session started

or
5.4.2. If RFID Access Control is enabled on your charger, then you will authorize charge session by RFID Card (Authorize first and then plug)

1. Swipe card
2. Wait until the screen changes to “authorizing”
3. Insert the charging plug into the EV. Session will timeout after 60s
4. Charging session started

5.5. Stop Charging

1. Unplug any time (disconnect the charging plug from EV to stop charging session)
2. Session ended (return the connector to the holster)

5.5.1. Auto Restart

When a charging session is interrupted due to a temporary error condition, the charger will automatically restart charging when the cause of the temporary error condition returns to normal. Status indicator lights remain flashing RED until the error condition is resolved.

1. Temporary error conditions included: Over Current, Over Voltage, Under Voltage, and Over Temperature.
2. For Over Current (OC) conditions: The charging session will be stopped while OC occurs. After recovery from OC for 5 minutes, the charger will automatically attempt to restart charging three times.
3. When charging session stopped due to CCID trip, the charger will try to restart 3 times after every 15 minutes.

5.5.2. Power Outage Recovery

When power resumes after an outage, the charger restarts automatically with a delay ranging from 120 to 720 seconds. The variable delay is to avoid impacting the utility grid when multiple charge points in the same area attempt to resume charging simultaneously.

5.6. General Care

The exterior of the charger is designed to be waterproof and dust proof. There is no preventative maintenance required. To ensure proper maintenance of the charger, follow these guidelines:

• Despite the water resistance of the enclosure, it is preferred to not direct streams of water at the unit. When cleaning it, clean with a soft, damp cloth.
• Make sure the charging plug is put back in the holster after charging to avoid damage.
• Ensure the power cable is stored on the holster after use to avoid damage.
• If the power cable or the charging plug is damaged, contact Customer Support for replacement.

5.7. Customer Support

Visit www.fordpro.com for additional customer support. Call US Customer Support:
800-343-5338 or Canadian Customer Support: 800-668-5515 or email at
[email protected]

5.8. Limited Warranty

The Limited Warranty associated with your charger is subject to certain exceptions and exclusions. For the terms of the limited warranty visit FordPro.com.

Installer Check List

After installation of your Ford Pro charger, we recommend having the installation provider and you fill out this form and save a copy for your records. In the event of a customer service call, the information collected on this form may be useful to reference.

Filling this form out will save money on calling electrician to fill out later post-installation and will expedite customer service calls into the customer service center.

This form is recommended as a place to capture information that is commonly asked or that may be useful for diagnosis of potential issues and assistance with troubleshooting of your Ford Pro charger. Ford Motor Company and Ford Pro cannot guarantee the accuracy of the information collected in this form. Neither Ford Motor Company nor Ford Pro shall be responsible for completion or verification of the form, or any costs or expenses related to completing this form or verifying the information provided.

1. Customer Information: (Optional)

Name:|
---|---
Address:|
Phone:|
Email:|

2. Serial Number of the Unit:

Serial Number (Located on the left side of the charger)

3. Installation Information:

Install Date:|
---|---
Brief Description of Charger Location (e.g., inside or outside, home or depot, post or wall-mounted)|
Protective Equipment Installed?| Bollards| Wheel Stops| etc.

4. Electrical Information:

Max Current Switch Setting, if appli- cable (if your charger has a hard- ware dip-switch, what is the current setting?)|

Electrical Information Specifics – circle in the table below or fill out in the last column the breaker size, amp output rating, wire size for L1 and L2, wire size for ground (GND), and wire coating.

5. Testing Information

No
Additional Notes or Comments

6. Inspection Information

Has the installation passed any required inspections?| Yes| No| If so what date:
---|---|---|---

7. Installation Provider Information

Company Name:|
---|---
Company Electrical License performing work under:|
Date:|

Ford Pro Support

Telephone:
US Customer Support: 800-343-5338
Canadian Customer Support: 800-668-5515

Website:
Fordpro.com

Email:
[email protected]

This document contains a general description of available technical options only, and its effectiveness will be subject to specific variables including field conditions and project parameters. Ford Pro does not make representations, warranties, or assurances as to the accuracy or completeness of the content contained herein.
Ford Pro reserves the right to modify the technology and product specifications in its sole discretion without advance notice.

Limited Warranty

The Limited Warranty associated with your product is subject to certain exceptions and exclusions. For the terms of the limited warranty please contact Ford Pro or Model e support.

FAQ

Q: What should I do if I encounter issues with the cellular connection?

A: If the cellular connection is not optimal, the charger will default to Ethernet and then Wi-Fi. For further assistance, contact Ford Pro Charging.

References

• kgf.cm

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