NUVVE EVSE-B PowerPort3 Ultra Installation Guide

NUVVE EVSE-B PowerPort3 Ultra

APPLICABILITY
PowerPort from Nuvve (part number EVSE-B-PX-TXX-HX-AXXX) is an AC charging station for electric vehicles that are provided with an SAE J1772 EV or SAE J3068 connector. (In Europe, designated IEC61851 Type 1 and Type 2.) This enclosure is rated IP54, ventilation is not required. PowerPort is supplied with an internal utility-grade meter.

This manual is intended only for use by qualified electricians for reference as to the work content and is not intended to reflect all the proper safety precautions. This document refers to specific versions of the product.

Legal: The information in this document is subject to change without notice and should not be construed as a commitment by Nuvve Corp. Nuvve Corp assumes no responsibility for any errors that may appear in this document. In no event shall Nuvve be liable for incidental or consequential damages arising from use of this document or the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without Nuvve’s written permission, and contents may not be used for any unauthorized purpose.

SAFETY INFORMATION AND OVERVIEW

WARNING – When using electric products, basic precautions should always be followed, including the following. This manual contains important instructions for Models EVSE-B-PX-TXX-HX-AXXX that shall be followed during installation, operation and maintenance of the unit.

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

Critical setting: PowerPort has an internal setting to limit the EV’s current drawn. The installing electrician must set this properly to not exceed the rating of the building circuit and the installed connector. See section “Critical Setting: Current Limit.”

Critical Setting: Torque of connectors on the supply connection to the Nuvve PowerPort must follow recommended torque. See section on Electrical and internet hookup.
Follow all applicable safety standards, building codes, and electrical codes. In the US, see NEC 625. This unit provides ground fault circuit protection. The circuit breaker feeding this unit should not have ground fault protection. Adapters, conversion adapters, and extension cords are not allowed to be used with this equipment.

Always use proper lockout and tag out precautions and comply with all national and local codes. Please review these instructions carefully before you begin the installation.

SUPPLIED COMPONENTS IN PACKAGE

• EVSE-B with cable and hanger attached
• PowerPort Installation and Setup Manual. (This document)
• User Quick Start sheet

Note: Please check SUPPORT.NUVVE.COM for document updates prior to attempted installation.

UNPACKING

• Unpack the shipping carton
• Remove the three Torx 25 bolts holding on the cover
• Remove the cover by sliding it up, towards the top of the unit
• Unplug the front panel display flex/ribbon cable from the board
• Unscrew the ¼ inch nut and washer holding the ground strap to the cover and retain nut and washer for reinstallation later
• Place back cover flat, and place top cover to side as shown in figure, being careful not to scratch the paint.

Figure: Open case — note light green ribbon cable, ground cable attached to cover, EV cable connected on right side and extended to outside of case. (Note: This image also shows the main power cable connected which will be done later in this procedure)

CRITICAL SETTING: CURRENT LIMIT
A branch circuit should be dedicated to only this device. One of the following must be followed, most commonly the “Typical setting”. If the Typical Setting is appropriate, other current setting sections can be skipped. If not, it may be helpful to read the section below “Current Limit Logic by PowerPort” to understand the three ways that the current limit is set.

Typical Setting

• The label on the side of case gives the “Branch Circuit Protector” size.
• Look at the label on the unit being installed.
• Install a circuit breaker or fuse of that size
• Skip to section “Physical Mounting”

Insufficient Ampere Capacity on Branch Circuit
If site location’s Branch Circuit Protector cannot support amperes on EVSE-B label, then set Dial to the corresponding position (see “Set Dial Position”)

Replacing cable with one of different Ampere capacity

• If cable to EV is being replaced or changed.
• Determine new cable and connector rating.
• Note: Rating is normally printed on the side of the cable & connector.
• Determine Branch Circuit Protection rating.
• Look up cable and breaker amps in table below to find the dial position number or letter.
• Set Dial position per below (see “Set Dial Position”)

All values in amperes|

Dial Position

---|---
Minimum Cord set rating|

US NEC Breaker Size

|

UK/EU Breaker

|

Size

12| 15| 13| 0
16                                                20 16|  | 1
20| 25| 20| 2
24                                                30 25|  | 3
32| 40| 32| 4
40                                               50 40|  | 5
48| 60| 50| 6
56                                               70 –|  | 7
63| 80| 63| 8
72                                               90 –|  | 9
80| 100| 80| A
Reserved|  | B
Reserved| C
Reserved|  | D
Reserved| E
Has not been set — Original Position from Factory|  | F

Set Dial Position (if needed)

• Note: The position of the dial (rotary switch) controls a signal from the Nuvve PowerPort to the EV that should limit how many amps any car plugging in to it will draw.
• To change this setting, first, access the dial:
• With the power off, remove the green “VEL” board, held down by four small screws and a pull-out 54-pin connector (requires a firm pull). Turn VEL board over.
• Find the rotary switch, with positions 0 through F (see figure, below). As manufactured, it should be set to “F”, meaning that the manufacturer setting has not been altered.
• Determine your installation’s “Breaker Size” and “Cordset Rating”. In the table, pick a line that is not greater than either. For breaker size, be sure to choose the correct column, either for a US NEC breaker or UK/EU breaker.
• Set the arrow of the rotary switch, using a small flathead screwdriver, to point the arrow to the number or letter in the column “Dial Position” below; this sets the maximum Amps that the EVSE will allow the EV to charge.
• If changed, use a permanent marker to update the input and output Amp ratings on the label on side of the case. (An example of this label is shown above.)
• If EVSE-B is installed in any of the countries CH, DK, FR, UK, where national codes prohibit automatic retry after a ground fault, the installer must ensure that dip switch 4 is set to “on”. The “on” setting prevents any automatic retry—thus the user must remove the cable, wait, and plug back in to achieve a retry after fault.

Current Limit Logic by PowerPort

This section gives an explanation not needed for a standard install, but helpful to understand under special situations.
Any EVSE, by cross-industry standards, must signal to the EV the maximum charging current the EV can draw. The EV is then responsible for limiting current.

In PowerPort, the maximum current as manufactured is a fixed, built-in number, set during manufacturing. (This is determined by component ratings and corresponds to the last number in the SKU, for example, 80 Amps for a SKU ending with “-A080”. With the switch in its initial setting of “F”, the factory-set maximum current is used. If the field electrician needs to change this maximum, for example, if the branch circuit rating is too small or if EV cable is replaced with a lower-amp cable, the electrician can alter the built- in maximum by just turning the rotary switch per the above section “Set Dial Position”, thereby also overriding the factory setting. Additionally, if the EVSE is being used for grid services, a Nuvve-trained EVSE Technician can be called to field inspect and add or change maximum current.

The EVSE Technician setting, if added, overrides both the rotary switch setting and the manufacturer’s built-in setting.

PHYSICAL MOUNTING

Wall mounting
Secure the case back of the electric vehicle charging station to the wall in the desired location. IEC standards for charging stations require that the cord hanger, or the receptacle, must be located at a height between 0.4 m and 1.5 m above ground level. In environments with flammable vapor, such as automotive garages, North American standards require mounting the EVSE at least 460 mm (18 inches) above the floor.

Using a fastener appropriate for the mounting surface, attach the case back through the top middle mounting hole only. Level the back panel, then secure through the remaining mounting holes.

Pedestal mount
A separate accessory kit may be ordered for mounting the PowerPort in a location without a wall surface. Please contact Nuvve sales for more information about this option.

ELECTRICAL AND INTERNET HOOKUP

Install conduit (as required) for the power and internet connections. You may use the knockouts provided on the bottom (as shown) or the back of the case.Install conduit (as required) for the power and internet connections. You may use the knockouts provided on the bottom (as shown) or the back of the case.

The internet connection requires connection to a building router; the internet cable should have an RJ45 connection attached, to be plugged into the top of the red circuit board (see blue cable in diagram).

• Some jurisdictions require that the ethernet cable be routed in separate conduit available at the back or bottom. For interior wiring, it may be acceptable to run ethernet cable wire-tied outside of the power conduit.
• If no wired internet connection is available, ask for Nuvve’s instructions for mounting a Wi-Fi transceiver next to the PowerPort, to provide internet via existing Wi-Fi in a nearby room, building or parking lot. Nuvve can provide documentation and instructions, but the Wi-Fi device is provided and supported by a third party.
• Next, follow either “Single Phase” or “Three Phase” sections, as appropriate.

Single Phase

• Connect a dedicated 120V (level I) or 208 – 240V (level II), over-current-protected service to the two terminals, marked “L1” and “L2/N” in the figure. Connect the ground wire into the smaller terminal marked “G”.
• Critical setting: The three screw terminals for line power, above marked L1, L2/N, G, must be torqued according to wire size, as shown in the table. Torque units are given in inch-pounds and in Newton-meters.

4-6 (10-25 mm2)                              45 in lb (5.1 N•m)
8 (5-10 mm2)| 40 in lb (4.5 N•m)
10-14 (2-5 mm2)                               35 in lb (4 N•m)

Terminals to the right should already be connected to the EV cable. If not, they must be installed prior to operation and must be correctly torqued.

Three Phase

• The PowerPort may be used for 200V, 208V, 400V or 480V three-phase power. In the US, check with the customer to ensure that the choice of 208V or 480V three phase is consistent with the expected voltages of the vehicles at the location.
• All three-phase EV standards require neutral, therefore neutral must be connected when installing the three-phase PowerPort. Supply must be 4-wire Wye.
• Connect a dedicated, overcurrent-protected service to the four terminals toward the left side, as shown below, marked “L1”, “L2”, “L3”, and “N” in the figure. The left terminals are for the line supply (the right should already be connected to the EV cable. Connect the supply ground to the smaller terminal marked “G” and colored green or green and yellow.

• For L1/L2/L3 use wires of 2-50 mm2 (14 to 1/0 AWG) appropriate to ampere rating of branch circuit, strip to 20 mm (3/4 in). Strip G to 13 mm (1/2 in).
• Critical setting: Use a torqueing screwdriver and torque to 5.0 N·m (44 lbf·in).
• Important: For 480 V, the PowerPort power supply must be powered from L1 to N. If it is powered L1 to L2, the 480V line supply will burn out the power supply. Installing electrician must check this before powering up a 3-phase EVSE.

Close EVSE and test

• Connect ribbon cable and ground wire, insuring they are not pinched when case closes.
• Install the cover to the back panel. Engage the top flange of the cover over the top edge of the back panel. Ensure the display connector wire is not pinched by the cover. Ensure the cover mounting holes align with holes in the bottom flange of the back panel.
• Secure the cover with the 3 Torx screws provided.
• When it is safe to do so, remove the lock-out tag-out and energize the circuit breaker that supplies branch power to the device.
• TEST: The power indicator light should illuminate when power is applied. The red “Error” light will blink for about 30 seconds each time the EVSE powers up. After the error light goes out, an EV can be plugged in to test correct charging.
• TEST: Connect the cord and connector from the EVSE to an electric vehicle. (For user education, the ideal vehicle is one of those owned, or to be charged at this location, with the vehicle owner or a site manager present.) After a few moments of delay the amber charging light should illuminate indicating that the EVSE is charging the vehicle. Charging should work whether the internet is connected correctly or not.
• TEST: If internet was connected, the blue internet light should illuminate. If the internet has not been set up correctly, the blue internet light may blink, indicating that EVSE-B is connected locally, for example to a building router, but is not communicating with a Nuvve server. Solid blue means both connected locally and connected to a Nuvve server. Blinking blue light can be addressed by a Nuvve technician.
• To set up the EVSE for GIVeTM, remote metering, or other advanced functions, a Nuvve-trained EVSE Technician should service the unit after the electrician has installed it and confirmed that power and internet are connected. These settings include the appropriate TSO, ISO or RTO, which is used to identify the correct Nuvve server to connect to.
• The EVSE is provided with an integral AC ground fault protector, and a DC ground fault protector (The DC ground current is presently a European requirement). In the event of excessive ground fault current, the EVSE will disconnect power to the vehicle and the red error light will blink. It will retry to restore service up to five times, waiting an increasing time with each retry. If the ground fault persists after that, the EVSE will remain in a fault condition with the red light blinking. To manually reset the fault (for example, if automatic attempts fail), the user must disconnect the charging connector from the vehicle, wait five minutes, then reconnect the cable to the vehicle again. Alternatively, the power to the EVSE may be cycled off then on.
• NOTE: If EVSE-B is installed in any of the countries CH, DK, FR, UK, where national codes prohibit automatic retry after a ground fault, the installer must ensure that dip switch 4 is set to “on”. The “on” setting prevents any automatic retry—thus the user must remove the cable, wait, and plug back in to achieve a retry after fault.”
• The electrical and internet installation and testing is now complete.

INSTRUCTIONS TO USER

The installer should point out this section to the driver or property owner. It contains user operation and maintenance instructions that provide more detail than the “User Quick Start” sheet.

Cautions: The EVSE should not be opened by the customer due to risk of shock and because there are no user-serviceable parts inside. The EVSE contains arcing parts (it arcs when disconnecting the connector from the EV, and when the internal relay opens); if installed in an area with flammable or explosive vapors, it should be installed at least 460 mm (18 inches) above the floor and should not be used when such vapors are present. Check any labels on the outside of the EVSE for possible additional region-specific warnings.

Connecting:
On the label pictured above, check that the green “power” light is on (top indicator in figure), plug in the EV, and insure that the amber “Charging” light turns on. The red “Error” light should be off (possibly after blinking 30 sec. when the EVSE is first powered up.) Once the EV is connected, for extra assurance that it is charging, check the EV’s normal charging indicator, and/or check any app you have that gives information like the rate of charging or the expected time until charged.

Troubleshooting

1. If the green light is not on, check for any on/off switch the electrician may have installed on the wall or inside the building, then check the breaker panel and find the main breaker and the specific breaker for this unit. All must be on.

2. If the amber “charging” light does not illuminate when the connector is put in the EV, check for debris in the connector and around the inlet on the EV. Sometimes dirt, insects, or other debris prevent the connector from going fully in, thus preventing a connection. When a clean connector is inserted, on the Type 1 connector there should be a mechanical “click”, and on the Type 2 connector, there may be a click as the lock engages to hold the connector in place. If it still does not charge, check whether the EV battery is already full. Check if there is a charging control system at this EVSE, for example, to stop charge during peak electric load hours. Finally, if charging still does not start, the user should try the same car on a different EVSE, or a different car on this EVSE, in order to determine whether the car or EVSE are the issue. If the EVSE still fails to charge the vehicle, technical support should be consulted.

3. If the blue “Internet” light is not steadily on: If the blue bulb is dark, the EVSE is not connected to the internet in the building, so, check the internet cable going from the EVSE to the building router, and check operation of the internet connection. If the blue bulb is blinking, the internet is connected but the server is not responding. The user can contact Nuvve, or simply check again to see if the server has recovered; if not, request technical support.

4. If the red “Error” light is blinking. (It is normal to blink 30 seconds when power is first connected.) If error light blinks during charging, charging will stop, and it is permissible to retry by unplugging and replugging the cord-set from the vehicle inlet. If allowed in your jurisdiction the unit may automatically retry several times. Blinking means a
   “ground fault” which often is simply caused by moisture on or in the connector; if damp, try removing and cleaning out the connector, or if time allows, leave it to dry out in the air, then retry. If these do not fix the blinking red light, a qualified service person should be consulted.

5. Red “Error” light is continuously on. Red light staying on means that the EV has tried to draw more current than is permitted. If this occurs the first time the EVSE is used, or the first time a high-current-load car is used, it could be a problem with configuration settings of the EVSE. Otherwise, this may be due to a problem with the car drawing more than is permitted.

6. If the red error light persists on or persists blinking when not plugged into a car, do not use the EVSE. The unit must be serviced prior to any further use.

Moving and storage:
An installed PowerPort is directly connected to the electric system and should be removed only by a qualified electrician. Care should be taken to protect the unit from physical and cosmetic damage when moving or storing the unit. The unit should be kept dry during storage.

References

• Nuvve Help Center

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