Black Box EVEMS240-100 Electric Vehicle Energy Management Systems Instruction Manual

Black Box EVEMS240-100 Electric Vehicle Energy Management Systems

Instruction Manual

INSTALLATION MANUAL

• MAIN POWER SUPPLY MONITORED
  240-208V / 120V, Single Phase – 60, 100, 125, 150, 200 Amp

• ALIMENTATION PRINCIPALE
  240-208V / 120V, Monophasé – 60, 100, 125, 150, 200 Amp

• MAX POWER OF DEVICE CONTROLLED
  240-208V, Single Phase – 50 Amp Resistive Load
  240-208V, Single Phase – 40 FLA

• DISPOSITIF DE PUISSANCE MAXIMALE CONTRÔLÉ
  240-208V, Monophasé – Charge résistive 50A
  240-208V, Monophasé – 40 FLA

• EV CHARGER TO BE CONTROLLED
  240-208V, Single Phase – 20 Amp up to 48 Amp Load CHARGEUR EV À CONTRÔLER
  240-208V, Monophasé – 20 Amp up to 48 Amp Charge

• MODEL NUMBERS BY TYPE
  EVSW240-100 for 60, 100 Amp Electrical Service Beakers EVSW240-200 for 125, 150, 200 Amp Electrical Service Beakers

Introduction

The contents of this manual are subject to copyright protection and other intellectual property protection of Black Box Innovations Inc. and its licensors. Without the written consent of Black Box Innovations Inc. this installation manual cannot be modified, reproduced, or copied. The following logos are trade names or trademarks of Black Box Innovations Inc. in the United States and Canada. If you would like more information, please request it.

SPECIFICATIONS

This device has a monitoring system that can protect an electrical distribution circuit by switching a load on or off based on its main breaker size and on what the system usage is. It will act to prevent systems connected to it from overloading the electrical distribution circuit by turning off the power to the load connected to it for the duration that the computational algorithm determines it is needed as related to the main breaker sizing.

Cu 75°C: 40 in-lbs_
Contactor Insulation System| 120°C, Class B
Frequency| 50 or 60 Hz
Operation ambient temp.**| 34°F to 104°F (1°C to 40°C)

Dimensions and weight are approximate figures and can change without notice.

Model Naming Convention

• Device Name, Voltage – Max Main Service Breaker Size
• EVEMS240 – 100
• EVSEMS40 – 200

Operation After Power Outage
In the event of a power outage, the device automatically restores the power supply to the vehicle charging station or receptacle when power returns and the algorithm determines that the current draw and other factors are under the setpoint for the determined period set by the installer.

INSTALLATION DIAGRAMS

STEP 1: CHECK THE CONTENTS OF THE PACKAGE

• Model#: DEVICEXXX-XXX
• 1 x Controller & enclosure,
• 2 x Current monitoring devices
• 1 x Bag including miscellaneous pieces,
• 1 x Installation instructions

STEP 2: PREPARING FOR THE INSTALLATION

1. Disconnect power to all devices being worked on or within an unsafe distance to the working area.

2. Select the device installation location.

   •  The recommended place for the device to be installed is directly above the main panel and with adequate air circulation. See Installation Diagram for suggested locations. Other locations are acceptable.

   • NOTE:
     The DEVICE controller must be mounted so that the nameplate remains visible at all times. It must not be installed in the orientation with the cover facing the ground.
     DO NOT install the device:

   •  Outdoors

   •  In a location with a high level of risk as defined by local electrical codes or in a hazardous location. – for example, nearby flammable materials, explosives or fuels, chemical products, and hazardous vapors.

STEP 3: INSTALLATION OF THE DEVICE

1. Remove the two cover screws and enclosure cover.
2. Attach the device securely to the desired location. Do not mount with the cover plate facing down.
3. Remove the black cover of the internal control partition by unscrewing the two screws inside the enclosure.
4. Install current monitoring devices on the main service wires to be monitored by clipping them onto each mainline paying attention to the arrow inside the window and labeling that indicates the direction of current flow and orientation of connection. Current monitoring devices should be installed so that no part of them will directly conduct electricity from exposed live parts. Ensure the closing clip is secured shut and fastened with a zip tie. Fasten the current monitoring devices in place with the zip-ties. Review and observe all local safety procedures when installing and working near live parts.
5. Ensure main lines lugs have not come loose with the installation of current monitoring devices.
6. Install the current monitoring device wire leads from the service area to the device control partition area ensuring the polarity of the leads remains as from the factory. (DO NOT coil wires near any other 120/240V wires as this may cause improper operation. DO NOT short wire leads together or to ground at any time. Install leads with mechanical protection from damage.)
7. nsert the two blue current monitoring device connectors into the corresponding two blue receptacles on the control board. Maintain wire polarity in the blue connectors and ensure wires and connectors are seated well in each receptacle.
8. set up switches and observation time dial as indicated in the chart and diagram on the next page or the back of the cover. These are located on the control board.
9. Re-install the cover of the control partition inside the enclosure by reinstalling the screws removed previously and tightening them until snug. Be sure not to pinch any wires or strip the screws.
10. .Install electrical lines from the supply breaker for the controlled device to the marked LINE SIDE of the contactor and bonding/ground attachment. See Torque Settings on page 3.
11.  Install electrical lines from end device to be controlled (ie: EV charger) to LOAD SIDE of contactor and bonding/ground as required by local electrical codes. See Torque Settings on page 3.
12. Install enclosure cover. Check for ground faults and when safe to do so, energize. (Note: The contactor will not close until a computational observation time of between 0 – 10 minutes. The algorithm must be satisfied the system will remain below 80% of the rated main breaker and other values included in it. This is partially dependent on the setting of the timer adjustment screw (white) on the control board. If this observation time is too long it can be adjusted by turning this dial setting counter-clockwise but this should not be set below 1 minute to avoid contactor chattering.)

See setting diagram chart and continued instructions

SETTINGS CHARTS

See the inside cover of the device for settings. There you will find the setting applicable to the device model and generation you have. Only use the setting appropriate for the model of the device. For example, the settings for an EVEMS240-100 are for electrical service sizes of 100A and under. While the settings for EVEMS240-200 are for service sizes of 125A and over. The chart provided here is for reference only and may differ from the generation you are using.

STEP 4: TEST FOR OPERATION
Test devise for correct operation.
Warning:
Warranty VOID if any devices are installed incorrectly.

Main Electrical Service Monitored Breaker Size| End Device Controlled Max Current Draw| EV Charger Suggested Breaker Size For

80% Load

|

DIP

Switch

1

|

DIP

Switch

2

|

DIP

Switch

3

|

DIP

Switch

4

|

DIP

Switch

5

---|---|---|---|---|---|---|---
60| 20| 25| OFF| OFF| OFF| OFF| OFF
60| 24| 30| OFF| OFF| OFF| OFF| ON
70| 20| 25| OFF| OFF| OFF| ON| OFF
70| 24| 30| OFF| OFF| OFF| ON| ON
90| 30/32| 40| OFF| OFF| ON| OFF| OFF
90| 40| 50| OFF| OFF| ON| OFF| ON
100| 24| 30| OFF| OFF| ON| ON| OFF
100| 30/32| 40| OFF| OFF| ON| ON| ON
100| 40| 50| OFF| ON| OFF| OFF| OFF
100| 48/50| 60| OFF| ON| OFF| OFF| ON
125| 30/32| 40| OFF| ON| OFF| ON| OFF
125| 40| 50| OFF| ON| OFF| ON| ON
125| 48/50| 60| OFF| ON| ON| OFF| OFF
150| 30/32| 40| OFF| ON| ON| OFF| ON
150| 40| 50| OFF| ON| ON| ON| OFF
150| 48/50| 60| OFF| ON| ON| ON| ON
200| 30/32| 40| ON| OFF| OFF| OFF| OFF
200| 40| 50| ON| OFF| OFF| OFF| ON
200| 48/50| 60| ON| OFF| OFF| ON| OFF

Below Settings are for Main Breakers Rated at 100% Continuous Load Only

All settings are applicable for EV chargers or other loads that tolerate switching their power off when required.

MAINTENANCE

Do not use any cleaning solvents on the devices. Electrical connection must be inspected, maintained, and re-torqued every year by qualified personnel to maintain safe and proper operation. The interval may be increased in areas with high ambient temperature variance

TROUBLESHOOTING

Contactor does not close (energize) at the initial device powered on: There is an initial delay when powered on while the computer algorithm is checking the electrical service. The contactor will not close until a computational observation time elapses between 0 – 10 minutes. During this time the current draw on the main electrical service wires must remain below threshold current values of 80% of the main breaker size. This is also dependent on the setting of the timer adjustment screw (white) on the control board referred to in step 8 and the chart in the instructions and other algorithmic values. If this observation time is too long it can be adjusted by turning this screw counterclockwise. You can check for contactor operation by turning this adjustment all the way counterclockwise and waiting for the current on both monitored main service wires to drop below 80% of the main service breaker rating for a short time as associated with the internal algorithm. The contractor should close shortly after this happens. This adjustment must not be left in this position but should be set above 1 minute to avoid contactor chattering and premature failure. If this test shows the device is not working, then check for 240/208V power at the line side terminations on the contactor. If there is power present, next check that both wire connectors (stack-ons) on the terminals plugged into the line side of the contactor are secure. Once this is confirmed, then check that the wire connectors on each side of the contactor coil are secure. If they are secure, next check the field-installed wires in the contactor lugs on both the line side and load side are properly installed and that voltage is present on the line size wires. Ensure the current monitoring device connections are the correct polarity. Ensure the current monitoring device wires and connectors are fully seated in the respective connector and receptacles. If these items all have been checked and the issue is not resolved, please de-energize and contact the manufacturer.

Improper operation of contactor:
Check if the length of the current monitoring device lead wires are coiled close to other 120/240V lines and if so move them away from the area as this can cause improper operation. Next check if the current monitoring devices are closed securely. If they are check if the current monitoring devices are installed in the correct orientation with the arrow shown inside the current monitoring device eye (window opening) pointing in the direction of the current flow. If the orientation is correct, then verify that both service wires are consistently well below the operational current specifications for up to 15 minutes (depending on the setting of timer adjustment) with an amp meter. Ensure the current monitoring device connections are the correct polarity. Ensure the current monitoring device wires and connectors are fully seated in the respective connector and receptacles. If all these items are verified and improper operation still exists, please de-energize the device and contact the manufacturer.

Contactor chatters on and off or makes loud humming noise:
Verify that the timer adjustment screw (white) on the control board is set approximately ½ way between the left and right rotation. If adjustment is needed insert a screwdriver and adjust accordingly. Reset power to the device. The farther this is set clockwise the more time the computer algorithm will watch the service before allowing the load side (ie: EV charger) to energize. Ensure the current monitoring device connections are the correct polarity. Ensure the current monitoring device wires and connectors are fully seated in the respective connector and receptacles. If this is completed and the contactor is still chattering or making a loud noise, please de-energize the device and contact the manufacturer. The device is built with noise isolators between the contactor and the enclosure. If the screws that attach the contactor to the enclosure are overtightened any humming sound may be amplified. These screws can be adjusted to allow for acoustic separation.

INFORMATION

This document contains important instructions which must be followed during the installation, maintenance of this device.
Notes
After installation verify that the device is securely attached to an adequate structure in a well-ventilated location. It is the installer’s responsibility to verify that the electric power source is adequate for the use of the device. Do not use any solvents to clean this device. Do not paint or apply exterior finishing to this device. Do not use this energy manager with end devices that require constant power.

Cautions
The installation of the device must be done to the latest electrical code requirements and with the consultation of, and according to the manufacturer’s specification and guidelines of both the Electrical Vehicle (EV) and the Charging Station. This device will shut off and re-energize electricity to both the Electric Vehicle, its Charging Station, or other load-side devices without notice.

Warning
Read all documentation provided by the device manufacturer before using this product and follow the installation and setup procedures. Always disconnect any and all sources of power before starting work.Do not modify, repair, or dismantle the device. Never introduce water or any other liquids to the area around or on this device. Do not install the device near flammable materials, explosives or fuels, chemical products, and vapors. Do not install this device in a hazardous or wet environment or location Disconnect this device immediately if defective or damaged in any way and contact the manufacturer. Any improper use of the device could result in serious injuries, death, or damage to property. Any improper use of the device can cause damage which will void the warranty. Never use the device above or below the temperature range of 34°F to 104°F (1°C to 40°C). The devices must be always kept free of frost and water vapor.

Feedback
We are always happy to hear your feedback on our products of this manual. We look forward to hearing from you. Please email all comments to customerservice@blackbox-in.com. You can also contact us by clicking on the message us button on our website at www.blackbox-in.com.

Limited warranty

1. Black Box Innovations Inc. warranties this device against any defects for a period of one year from the date of shipping. The warranty is limited to the components and equipment supplied by Black Box Innovations Inc.
2. lack Box Innovations Inc. may undertake repair or replacement, at the site or the manufacturing location, at its option, of the defective material only after an evaluation has been made by its representative.
3. f, in the opinion of Black Box Innovations Inc. installation has been done incorrectly, or the device is used inappropriately, or repairs have been done by unauthorized personnel other than representatives of Black Box Innovations Inc., the warranty will be automatically void.
4. lack Box Innovations Inc. will not be held liable for damages or delays and will not be required to pay the transport cost of the charge controller claimed to be defective.
5. prior written consent must be made by Black Box Innovations Inc. before repairs, replacement, or modifications for compensation to be made.
6. Black Box Innovations Inc. shall not be liable for any indirect damages or delays caused by inadequate workmanship, or materials on devices install. This also applies if the installations are not made in accordance with the manufacturer’s instruction, local electrical codes, as well as specifications of devices powered after this device.
7. Black Box Innovations Inc. shall not be liable for any direct or indirect damages or delays for any devices that are connected to this device that can not tolerate having supplied power switched off for any time period specified by the device or when the device is in need of repair or maintenance.
8. Any device or accessory supplied with this device to be installed or connected remotely from the charge controller will be guaranteed by the manufacturer only under the conditions mentioned in paragraphs 6 & 7 and in accord with the rest of this document.
9.  Any repairs made at the Black Box Innovations Inc. factory are warrantied for 30 days from the date of repairs.
10.  Any components supplied for repairs are warrantied for the remaining of the warranty on the original product or 90 days whichever is longer.

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References

• EVEMS - Electric Vehicle Energy Management Systems – Black Box Innovations

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