Level 2 Dual
Level 2 Dual
• The charging station power supply must only be installed by licensed electricians.
• Make sure that the materials used and the installation procedures both follow local building codes and safety
standards.
• The information provided in this manual in no way exempts the user of responsibility from following all applicable
codes or safety standards.
• This document provides instructions for the charging station and should not be used for any other product.
Before installation or use of this product, review this manual carefully and consult with a licensed contractor,
licensed electrician, or trained installation expert to make sure of compliance with local building codes and
safety standards.
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• Operation is subject to the following two conditions: (1) this charging station may not cause harmful
interference, and (2) this device must accept any interference received, including interference that may cause
undesired operation.
WARNING: This equipment is intended only for charging vehicles that do not require ventilation during
charging. Please refer to your vehicle’s owner’s manual to determine ventilation requirements.
WARNING: Do not use extender cables to increase the length of the charging cable. Maximum length is
limited to 25 feet as regulated by the National Fire Protection Agency.
WARNING: Do not drag the charging point by the input power cord.
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Contents
1 Introduction ................................................................................................................................................................. 5
1.1 Product view .................................................................................................................................................... 5
1.2 Box Contents ................................................................................................................................................... 6
2 Installation ................................................................................................................................................................... 7
2.1 Before installation ........................................................................................................................................... 7
2.1.1 Safety check...................................................................................................................................... 7
2.1.2 Grounding instructions .................................................................................................................... 7
2.2 Tools & parts required for installation ......................................................................................................... 8
2.3 Installation Readiness .................................................................................................................................... 8
2.3.1 Grounding Instructions Reminder .................................................................................................... 9
2.4 Adjusting the Charging Station Maximum Current Output Setting (Optional).............................................. 9
2.5 Input Power Connection ................................................................................................................................ 11
2.6 Install the Charge Station .............................................................................................................................. 12
3 Specifications ........................................................................................................................................................... 14
3.1 Product Specifications................................................................................................................................. 14
3.2 Waterproof Connector Specfications ........................................................................................................ 15
4 Operations ................................................................................................................................................................ 17
4.1 Charging Status Indicators ......................................................................................................................... 17
4.2 Charging your Electric Vehicle (EV) ......................................................................................................... 18
4.2.1 Connect and Charge..................................................................................................................... 18
4.2.2 Stop Charging................................................................................................................................ 18
4.2.3 Auto Restart ................................................................................................................................... 18
4.2.4 Power Outage Recovery .............................................................................................................. 19
4.3 General Product Care .................................................................................................................................. 19
5 Customer Support ................................................................................................................................................... 19
6 Limited Warranty ..................................................................................................................................................... 20
7 PowerCharge™ Pro-lightning Base Template .................................................................................................... 23
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1. INTRODUCTION
This user manual applies to PowerCharge™ Pro-Lightning Series Level 2 AC Charging Stations for Plug-in Electric
Vehicles (PEVs) and Battery Electric Vehicles (BEVs).
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QTY Hardware
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2. INSTALLATION
CAUTION: Avoid touching or pressing the OLED screen all times, as this may result in damage to the OLED
screen.
The charging station 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 charging station, make sure you have read all these instructions in this manual and fully
understand its contents.
Appropriate protection is required when connecting to a power supply. The tools and parts in Section 2,2 shall
be used.
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Torx Screwdriver All T30 Bit Included For securement of side panels
• Disconnect the power supply to the charging station and verify no power is present before installing,
adjusting, or repairing the charging station. Failure to do so may result in physical injury or damage to the
power supply system and the charging station.
The charging station 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 charging station, make sure you have read these instructions in this manual and fully understand
its contents.
Appropriate protection is required when connecting to a main panel/switchboard. The tools and parts used as
outlined in the section “Tools & Parts Required for Installation”.
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Prior to mounting, locate an available electrical source that can support the following input requirements for the
charging station per National Electric Code (NEC) requirements:
• Output setting set at factory. Check decal placed on the junction box to verify the factory setting.
• 32A Maximum Output Setting (Default Factory Setting): a DEDICATED CIRCUIT rated for 40A; 208-240
VAC, 50-60 Hz, Single Phase must be used. Circuits rated greater than 40A may also be used.
• Lower amperage setting optional. If a reduced setting is desired, contact the factory for technical support.
• The PowerCharge™ Pro-Lightning is available with single or dual power feed. This unit can only be wired
as per decal instructions on the junction box. If equipped with optional single-circuit feed, it will be noted
on decal placed on junction box.
CAUTION: The service wiring in this section is specific to North America only. Before installing the charging
station, identify the type of utility service connection available onsite. If you are unsure about the type of
connection available at the service panel, contact your utility service provider.
• Disconnect the power supply to the charging station and verify no power is present before installing,
adjusting, or repairing the charging station. Failure to do so may result in physical injury or damage to
the power supply system and the charging station.
• Electrical Power MUST remain OFF and DISCONNECTED before setting or changing the DIP switch (if
equipped). A non-conductive object MUST be used to adjust the DIP switch settings, failure to do so
may result in risk of electrical shock and damage to the equipment.
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The charging station product features the ability to adjust the maximum charging station current output to allow
the use of a 40A (or greater), 30A, or 20A Dedicated Circuit per charge port as follows:
• 40A Circuit Rating: To support 32A (7.68 kW) maximum charging station output
• 30A Circuit Rating: To support 24A (5.76 kW) maximum charging station output
• 20A Circuit Rating: To support 16A (3.84 kW) maximum charging station output
The current (amperage) output is set at the factory. The charging station may require one or two feed(s). The
default is to provide two (2) 208/240v, 40a circuit feeds. There is an optional single 208/240v, 40a feed
(This option is available during the order process), The junction box will be labeled as such if this option has
been configured. The charging station must be wired according to the diagram on the junction box (if
equipped).
Using the included 50-amp outdoor rated wire nuts, connect the incoming wires to the charger wires in the
junction box. Be sure to connect the L1, L2, and Ground wires accordingly. Each side of the charging station
MUST receive its power from a common circuit breaker.
Once all wires are properly connected, tuck neatly into the junction box and replace the cover, making sure it
has a tight seal.
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1. Choose the appropriate conduit in accordance with all applicable state, local and national electrical codes
and standards.
2. Connect copper wires with included 50 AMP wire nuts (if equipped).
3. Connect the circuit feed wires to the junction block in the junction box (if equipped).
JUMPERS
REQUIRED
WITH SINGLE
CIRCUIT FEED
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CAUTION: To reduce the risk of fire, connect only to a circuit provided with appropriate
overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70, and the
Canadian Electrical Code, Part I, C22.1.
CAUTION: 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.
Follow applicable accessibility requirements for the mounting position. The unit shall be mounted at
a sufficient height from ground such that the height of the storage means for the coupling device is
located between 24 inches (600 mm) and 4 feet (1.2 m) from ground per NEC Article 625.
Charger base may be concrete (recommended 18” x 18” x 18” with conduit stub-up in center.
Hollow composite-style base is also acceptable). Follow manufacturer installation instructions.
Mark the base bolt securement locations to position the charging station in the center of the base. If
using a concrete base, drill 5/8” holes to accommodate, included drop-in anchors. If using a
composite hollow base, use ½”x13 thread x 2” long stainless hex-head bolt with washer and nut.
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Use the three leveling bolts to verify all three sides of the charging station are plumb.
3a) Loosely attach rear panel to retractor using two ¼ - 20 x ¾ stainless screws, two ¼ - 20 stainless
nuts and two ¼ inch nylon spacers.
3b) Dry fit the back panel and retractor combo to the back of the PL2 and loosely attach using the
¼ - 20 powder coated screws provided. Mark the ground to accept two ¼ inch drop-in anchors for the
retractor base.
3c) Remove the back panel and retractor combo and drill and seat your anchor points.
3d) Secure back panel to retractor.
3e) Place the back panel and retractor combo into its final position on its anchors and secure to ground
as well as securing the back panel to the Pro-Lightning.
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4. SPECIFICATIONS
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INSTALLATION INSTRUCTIONS: Important: Turn off power before installing or removing connector. Product to be
used in accordance with local and national codes.
1. Strip wires 3/4” (19.1mm).
2. Align any frayed strands or conductors.
3. Pre-twisting unnecessary, Place stripped wires together with ends of insulation even.
4. Twist connector onto wires pushing firmly until hand-tight. Do not over torque.
5. Wipe sealant in and around conductors and connector opening while tightening, Do not reuse.
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4. OPERATIONS
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5. CUSTOMER SUPPORT
If the charging station is not operational or you need assistance, please contact:
PowerCharge™
500 Canal View Blvd, Suite 100
Rochester, NY 14623
585•533•4085
www.PowerChargeEV.com
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6. LIMITED WARRANTY
Limited Warranty for PowerCharge™ Pro-Lightning Series Electric Vehicle Charging Station
• PowerCharge™ Electric Vehicle Charging Station is warranted against defects in materials and
workmanship for three (3) years from date of purchase for the electronics and ten (10) years from the
date of purchase for the housing and optional cable retractor system.
• Cables, J1772 Connectors and retractor rope are wear items and warranted against defects in materials
and workmanship for ninety (90) days from purchase.
IMPORTANT: It is the Purchaser’s obligation to register the Charging Station with PowerCharge™ and failure
to do so may delay warranty support. This warranty is only valid to the original purchaser of the Electric
Vehicle Charging Station and is not transferrable. ALL WARRANTY CLAIMS MUST BE MADE WITHIN THE
WARRANTY PERIOD AND PROOF OF PRODUCT PURCHASE AND WARRANTY REGISTRATION NUMBER
MUST BE SUPPLIED. This warranty does not cover labor or the cost of freight to return the Electric Vehicle
Charging Station to PowerCharge™.
Registration: Please complete and return the accompanying Warranty Registration Card to:
PowerCharge™, 7464 W. Henrietta Rd., Rush, NY 14543
or email the product registration information to warranty@PowerChargeEv.com.
Subject to the exclusions from the Warranty coverage set forth below, PowerCharge™ warrants that, when used
under normal operating conditions, your Charging Station will be free from any defects in materials or workmanship
for a period (the “Warranty Period”) of three (3) or ten (10) years from the date of original purchase, based on the
area of the defect. If, during the Warranty Period, your Charging Station becomes defective in breach of the
Warranty, PowerCharge™ will, upon written notice of the defect received during the Warranty Period, either repair or
replace, at PowerCharge’s election, the Charging Station. The Warranty covers both parts and labor necessary to
repair your Charging Station but does not include any on-site labor costs related to un-installing or reinstalling the
repaired or replacement Charging Station or any component. Any replacement Charging Station or component so
furnished will be warranted for the remainder of the original Warranty Period.
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IMPORTANT:
1) You are responsible for the proper installation and maintenance of the Charging Station including the un-
installing of any defective Charging Station or component and the installation of a repaired or
replacement Charging Station or component returned to you. Installation and uninstallation shall be
performed only by a qualified electrician.
2) Any service or repairs beyond the scope of the Warranty above will be performed upon customer
approval at PowerCharge™’s then prevailing labor rates and other applicable charges.
3) Any Charging Station that is found by PowerCharge™ to be out-of-warranty or otherwise ineligible for
warranty services will be returned, repaired, or replaced upon customer approval at PowerCharge™’s
standard charges at the customer’s expense.
4) Please read carefully through the detailed descriptions of the WARRANTY, the EXCLUSIONS FROM
WARRANTY, and the DISCLAIMER AND LIMITATION OF LIABILITY listed below to assure that your
Charging Station is eligible for warranty service without additional cost to you.
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PowerCharge™ IS NOT LIABLE FOR ANY INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE OR CONSEQUENTIAL
DAMAGES, INCLUDING WITHOUT LIMITATION LOST PROFITS, LOST BUSINESS, LOST DATA, LOSS OF USE, OR
COST OF COVER INCURRED BY YOU ARISING OUT OF OR RELATED TO YOUR PURCHASE OR USE OF, OR
INABILITY TO USE, THE CHARGING STATION, UNDER ANY THEORY OF LIABILITY, WHETHER IN AN ACTION IN
CONTRACT, STRICT LIABILITY, TORT (INCLUDING NEGLIGENCE) OR OTHER LEGAL OR EQUITABLE THEORY,
EVEN IF PowerCharge™ KNEW OR SHOULD HAVE KNOWN OF THE POSSIBILITY OF SUCH DAMAGES. IN ANY
EVENT, THE CUMULATIVE LIABILITY OF PowerCharge™ FOR ALL CLAIMS WHATSOEVER RELATED TO THE
CHARGING STATION WILL NOT EXCEED THE PRICE YOU PAID FOR THE CHARGING STATION. THE LIMITATIONS
SET FORTH HEREIN ARE INTENDED TO LIMIT THE LIABILITY OF PowerCharge™ AND SHALL APPLY
NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY.
Some states do not allow for the exclusion or limitation of incidental or consequential damages for some products, so
the limitations or exclusions contained herein may not apply to you.
This Warranty is the entire and exclusive agreement between you and PowerCharge™ with respect to its subject
matter, and any modification or waiver or any provision of this statement is not effective unless expressly set forth in
writing by an authorized representative of PowerCharge™.
PC300-PRD320-202301-REV-A
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PRO-LIGHTNING
BOLT-DOWN TEMPLATE
FRONT
.625” .625”
2.50”
.625”
1”
PRINT INSTRUCTIONS:
1” PAPER SIZE: 8.5 x 11”
SET PRINT TO “DO NOT SCALE” / “ACTUAL SIZE”
CHECK PRINT TO ENSURE CORRECT SCALE
| 500 Canal View Blvd, Suite 100 | Rochester, NY 14623 | 585•533•4085 | PowerChargeEV.com