Installation - Power Source Wiring

The last step in the mounting process is to connect the wiring from the electrical service panel to the contactors in the contactor junction box. This will require running 2 sets of 3 x 6-8AWG within a 3/4 inch conduit from the electrical service panel to the EVCC evSmartPlug contactor junction box. In addition, if the EVCC will be connected to the Internet via Ethernet cable, proper data conduit runs and CAT6 cabling will be needed.

For the purpose of this installation guide, it is assumed that the electrical and data cable (Ethernet) infrastructure is in place leading up to the EVCC evSmartPlug including the 50amp service panel circuit breakers, conduit, 6 x 6-8AWG wiring, and Ethernet cabling (if needed).

Note that the circuit breakers must be rated for 125% of the maximum possible load of the installed receptacles.

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NOTE: Consult all applicable codes for breaker and wire sizing requirements.

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Before proceeding with this section, be sure to set the circuit breaker for the power source wiring to the OFF position. Do not restore power to the circuits until installation is complete.

‍Failure to follow these instructions could result in shock or electrocution.

Follow These Steps

Follow the steps below to supply the needed wiring to power the NEMA 14-50 outlets and the EVCC. You will need 4 x 6-8AWG 10stud ring terminals

Ensure the electric service panel possesses 2 x 240v dedicated circuits with 2 unused and new, dedicated, two-pole 50 amp circuit breakers, in accordance with local codes and ordinances.

‍NOTE: Some jurisdictions may require the use of a GFCI leakage protection circuit breaker at the panel if using NEMA 14-50 receptacles. Most EV chargers (hardwired and portable) possess their own leakage protection mechanism called a charge circuit interrupting device (CCID). Using a GFCI breaker and CCID in the same circuit can cause nuisance tripping. Thus, in this scenario, installing dedicated 40amp, hardwired, unmanaged, EV chargers are recommended instead of receptacles.

Prior to inserting the source power wires into the junction box, measure and cut the wire to the proper length so there will be about 4 inches of wire available inside the junction box.

Using the wire stripper, strip about 1/4 of an inch away of the insulation of the source power wires.

Using the crimp tool, crimp 4 x 8 stud 6-8AWG ring terminals to the bare ends of each of the 4 leg wires.

WARNING: Be sure these terminals are crimped securely to the wires so that a wire cannot break free of the terminal. Loose, bare wires can be hazardous in a high voltage enclosure.

Insert the 3/4in - 1 inch conduit fitting and wiring through the bottom of the contactor junction box.

On the power source conduit connector, remove the ring fastener screwed onto the fitting, then feed all of the wires through the bottom side cutout of the contactor junction box. From there, feed the ring fastener back through the wires and screw the ring tight to the conduit connector threads.

Fasten the left side receptacle source power ground wire to the left side ground terminal lug attached to the bottom left side of the contactor junction box.

Repeat this step for the right side receptacle ground wire.

With a Phillips-head screwdriver unscrew the two contactor screws from the left side contactor. Fasten the left side receptacle source power 1st and 2nd leg ring terminals to the respective termination points of the contactor as shown.

Do not fully tighten the screws as the EVCC power wires will need to be connected to these termination points in the next step.

Connect the Y terminals of the EVCC power wires to the respective legs of the left side contactor termination point as shown. Firmly tighten the Philips-head screws.

Connect the DINrail separator between the two contactors as shown.

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