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GM PowerShift Charger Installation Manual

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Installation Manual
Version 1.0 - April 2024

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Summary of Contents for GM PowerShift Charger

  • Page 1 Charger Installation Manual Version 1.0 - April 2024...

  • Page 2: Table Of Contents

    Preparation Wall Mounting Installing the GM Energy PowerShift Charger Installing the Charging Holster Raceways and Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27...
  • Page 3 Commissioning The Device Via Mobile App . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Pre-Commissioning Systems Check Commissioning Process Commissioning Change Device Maintenance Before Leaving GM Energy PowerShift Charger Installation Manual...

  • Page 4: Important Conventions

    Warnings indicate a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Cautions indicate a hazardous situation which, if not avoided, could result in minor or moderate injury, or that could result in property or equipment damage. GM Energy PowerShift Charger Installation Manual...

  • Page 5: Important Safety And Wiring Instructions

    This manual contains important instructions that must be followed during installation. WARNING To ensure that the GM Home Energy system (“the system”) will operate and perform safely and as intended, the system must be designed, installed, commissioned and placed into operation only by qualified persons, and in compliance with all product requirements, including, but not limited to: equipment integrated as listed and not exceeding capacities or ratings;...

  • Page 6: Safety And Compliance

    • Do not put tools, material or body parts into the electric vehicle connector • Do not use the GM Energy PowerShift Charger if the cabinet, power cord or charging cable is damaged or frayed, if the insulation material is broken or if the system shows any other signs of damage •...

  • Page 7: Installation Site Selection

    Installation Site Selection The GM Energy PowerShift Charger can be installed in both indoor and outdoor environments. It is necessary to consider the installation conditions and protection at the site. WARNING To reduce the risk of fire, electric shock or serious injury, do not install the system in or on any of the following: •...

  • Page 8: Service Wiring

    Service Wiring Ground Connection The GM Energy PowerShift Charger must be installed compliant with local codes and standards, and the main service must always have the Neutral connection to Earth Ground (PE). The GM Energy PowerShift Charger requires 240V single-phase connection with Earth Ground (PE).

  • Page 9: Federal Communications Commission Interference Statement

    Radiation Exposure Statement: This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance of 20 cm between the radiator and your body. GM Energy PowerShift Charger Installation Manual...

  • Page 10: Introduction

    When paired with the GM Energy Vehicle-to-Home (V2H) Enablement Kit, the GM Energy PowerShift Charger can also direct power from a Compatible GM EV back to the home. With bidirectional charge and discharge power, the GM Energy V2H Bundle (GM Energy PowerShift Charger and GM Energy V2H Enablement Kit) has the ability to provide power to a home in the event of a power outage.

  • Page 11: Before Installation

    To reduce risk of fire for 1 phase 240VAC input, in accordance with the National Electric Code, • ANSI/NFPA 70, the final branch circuit overcurrent device for the GM Energy PowerShift Charger • should be installed with rated current in accordance with DIP switch settings (reference section “Configuring the DIP Switches”).
  • Page 12 (installation manuals, user manuals, warranty information, etc.). https://www.gmenergy.gm.com/home/resources-and-support The GM Energy Home System is designed to meet North American safety standards. To prevent the risk of electrical shock and ensure proper long-term operation of the system, read and follow all instruction manuals and safety precautions.

  • Page 13: Recommended Tools

    Recommended Tools The following tools are recommended for the GM Energy PowerShift Charger installation: • Appropriate personal protective equipment (PPE) for the application • Tape measure • Pencil or marker • Power drill • 10 mm (3/8") concrete masonry drill bit (for installations in concrete wall) •...

  • Page 14: Important Safety Instructions

    CAUTION To avoid damage to the charger or personal injury, make sure the installation location is able to support the weight of the GM Energy PowerShift Charger. GM Energy PowerShift Charger Installation Manual...

  • Page 15: Installing The Gm Energy Powershift Charger

    INSTALLING THE GM ENERGY POWERSHIFT CHARGER Note: The GM Energy PowerShift Charger can be installed as a GM EV charger only (AC Power) or as part of the GM Energy V2H Bundle (AC and DC Power). Preparation 1. Open the top side of the box 2.
  • Page 16 5. Take out the unit (A), mounting bracket (B), two bags of screws (C) and Charging Holster (D) from the packaging GM Energy PowerShift Charger Installation Manual...
  • Page 17 • Watertight conduit connectors are required to maintain NEMA rating of device. Watertight connections are only required for external installations or internal installations where exposure to water may occur. Connectors may be up to 1-1/4" trade size. GM Energy PowerShift Charger Installation Manual...

  • Page 18: Wall Mounting

    (61 cm — 119 cm) *Recommended FLOOR CAUTION Install the GM Energy PowerShift Charger on a non-flammable support that is suitable to handle the weight of the unit. Note: • Ensure ambient temperature is between -40°F and 122°F (-40°C and 50°C) •...
  • Page 19 Drill a pilot hole at the locations marked with a 7/32" drill bit into the drywall and stud a depth of ~2-1/2". Drive the provided M8 lag screws through the Charging Holster, securing to the wall. Ensure screws have more than 1-1/2" engagement into solid wood GM Energy PowerShift Charger Installation Manual...
  • Page 20 Use at least a #12 drywall-rated anchor and screw set, following manufacturer instructions for mounting, to secure the Charging Holster to wall at the 2x locations marked. Ensure the screw head has sufficient contact to the Charging Holster GM Energy PowerShift Charger Installation Manual...
  • Page 21 3/8" masonry drill bit to a depth of ~2-1/2". Insert the 2x anchors and drive the provided 2x M8 lag screws through the locations marked, securing the Charging Holster to the wall GM Energy PowerShift Charger Installation Manual...
  • Page 22 Use the holster as a template to mark 2x screw holes in your wall at the desired location. Drill a pilot hole at the locations marked with a 7/32" drill bit a depth of ~2-1/2". Drive the provided 2x M8 lag screws through the locations marked, securing the Charging Holster to the wall GM Energy PowerShift Charger Installation Manual...

  • Page 23: Installing The Gm Energy Powershift Charger

    Installing the GM Energy PowerShift Charger 1. Place the unit onto bracket a. Horizontally align the slots on the back chassis of the unit to the corresponding hooks on the bracket b. Slowly slide down the unit until it sits firmly on the bracket Note: •...

  • Page 24: Installing The Charging Holster

    Before completing the following steps, ensure the Wall Mounting process (found on pages 18-22) is complete. Note: Ensure the position of the Charging Holster is within the range described in the “Wall Mounting” section on page 18. GM Energy PowerShift Charger Installation Manual...
  • Page 25 4. Mount the Charging Holster onto the wall using the M8 lag screws provided Note: Use the screws and screw anchors provided in the accessory kit. A drill might be needed for certain conditions. GM Energy PowerShift Charger Installation Manual...
  • Page 26 5. Re-insert the inner slot into the Charging Holster and fasten its two screws. Use M4x10 mm screws and Torx T20 head bit (Torque: 12 kgf-cm/10.4 lbf-in.) 6. Re-install the front cover onto the Charging Holster until it clicks into place GM Energy PowerShift Charger Installation Manual...

  • Page 27: Raceways And Wiring Connections

    • Remove the 14 screws from the sides of the middle cover • Remove the middle cover from the unit Note: After removing the 14 screws, keep them in a safe location nearby so they will not get misplaced. GM Energy PowerShift Charger Installation Manual...
  • Page 28 • With the back of the unit facing up, feed the AC wires through the right-side opening • Feed the DC wires (if applicable) through the left-side opening • Feed the communication cable and inverter wires (if applicable) through the left-side opening Comm & Inverter Bottom-fed wiring GM Energy PowerShift Charger Installation Manual...
  • Page 29 • Feed the DC wires (if applicable) through the left-side opening • Feed the communication cable and inverter wires (if applicable) through the left-side opening Comm & BDI Rear-fed wiring 5. Continue with connecting the wires; see the following sections GM Energy PowerShift Charger Installation Manual...

  • Page 30: Ac Wire Connections (From Power Grid)

    • Secure each conductor at the terminal with a Phillips-head torque tool (torque: 38 +/- 2 kgf-cm/33 +/-2 lb.-in.) 3. Once you have connected the AC wires, configure the DIP switches to set the maximum output current ratings GM Energy PowerShift Charger Installation Manual...

  • Page 31: Configuring The Dip Switches

    Configuring the DIP Switches The factory default output is 0A for the GM Energy PowerShift Charger. Use the DIP switches to configure the maximum output current ratings. 1 2 3 Pin Configuration Max. AC Output Example Circuit Breaker Amps (Default)
  • Page 32 Pin Configuration Max. AC Output Example Circuit Breaker Amps 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 GM Energy PowerShift Charger Installation Manual...

  • Page 33: Configuring Dip Switches During Initial Installation

    48A output current 1 2 3 3. Turn on the breaker to power on the GM Energy PowerShift Charger. When the LED lights up solid white, plug the Charging Coupler into the GM EV to start charging 4.

  • Page 34: Dc Wire Connections (Only If Installed With V2H Enablement Kit)

    DC Wire Connections (Only if Installed with V2H Enablement Kit) The GM Energy V2H Enablement Kit is required for DC wire connections. See GM Energy V2H Bundle System Installation Instructions available at https://gmenergy . g m . c om/for-home/installation-support GM Energy PowerShift Charger Installation Manual...

  • Page 35: Completing The Installation

    2. Hook the top features of the front cover, then the side hook features to the back cover, and then fasten the two screws (M4x10 mm Torx T20 head bit) securely (torque: 12 kgf-cm/10.4 in.-lbs.) GM Energy PowerShift Charger Installation Manual...

  • Page 36: Commissioning The Device

    3. Properly place the Charging Coupler into the Charging Holster CAUTION When the Charging Coupler is not being used to charge a GM EV, ensure that it is placed into the Charging Holster properly. DO NOT leave it on the floor/ground.
  • Page 37 Power Button again will resume the charging or Press and release discharging session *Discharge capabilities are only available when the GM Energy PowerShift Charger is paired with the GM Energy V2H Enablement Kit and a Compatible GM EV. GM Energy PowerShift Charger Installation Manual...
  • Page 38 OTA (over-the-air) software update in progress YELLOW BLINKING BLINKING Charger error SOLID Installation incomplete (DIP switch not set) *Discharge capabilities are only available when the GM Energy PowerShift Charger is paired with the GM Energy V2H Enablement Kit. GM Energy PowerShift Charger Installation Manual...
  • Page 39 EV4015 Critical component Wi-Fi temperature is invalid EV4016 Critical component MPU temperature OTP EV4017 GM Energy Inverter (BDI) is unavailable: SAFETY FAULT EV4018 GM Energy Inverter (BDI) is unavailable: SYSTEM FAULT EV4019 GM Energy Inverter (BDI) is unavailable: DCDC-FAULT EV401A...
  • Page 40 AC charging connector: AC charger DIP read fault or DIP switch is faulty EV4299 EV429A AC charger HW DIP switch setting is 0A The AC charging maximum current value is less than 6A EV429B EV500E Master CSU and OCPP communication failure GM Energy PowerShift Charger Installation Manual...
  • Page 41 Alarm Code Description EV5080 CAN Communication timeout with the GM Energy Inverter EV5014 Master CSU and IMD communication failure EV5016 Master CSU and AC charger communication failure EV5019 Master CSU and MCU communication failure EV9100 DC charging connector: Self-test failure...
  • Page 42 Visit https://gmenergy . g m . c om/for-home/installation-support to download the most recent commissioning app. For the intent and purpose of this section, the GM Energy PowerShift Charger will be referred to as the EVSE (Electrical Vehicle Supply Equipment). Pre-Commissioning Systems Check Power on all systems •...
  • Page 43 Do not plug in to EV. If the LED light is solid red for the EVSE, this indicates the DIP switches must be set. Please refer to the “Configuring the DIP Switches” section of this manual before proceeding. GM Energy PowerShift Charger Installation Manual...
  • Page 44 Select Scenario Commission Change Device Maintenance Device Connection Device Connection Device Info Device Settings Network Setting Network Setting Cloud Registration Firmware Upgrade Event History Device Info Device Info Firmware Upgrade Complete Complete Back to Startup GM Energy PowerShift Charger Installation Manual...
  • Page 45 2. Navigate to the installer website: https://euss-prod .musea2 .azure . e xt . g m . c om/ • If you are commissioning the equipment for the first time or performing maintenance, you will need to set up an account and agree to the terms and conditions GM Energy PowerShift Charger Installation Manual...
  • Page 46 • Sign in using user credentials. If you do not have an existing account, follow the prompt to create a new account • Each installer must create their own GM account; this is separate from the customer’s account 4. Input the GM Energy hardware order number if available Note: Customers will have received the order number as part of the receipt of their purchase.
  • Page 47 5. A verification code will be generated • Copy the code as instructed 6. Return to the PowerShift Install App • Paste the code and click “Login” GM Energy PowerShift Charger Installation Manual...
  • Page 48 (Includes device connection, device setting, cloud registration and device information) 1. Select “Commission new device” 2. Select “New EVSE” if installing a new GM Energy PowerShift Charger without the GM Energy V2H Enablement Kit GM Energy PowerShift Charger Installation Manual...
  • Page 49 *Available on select Apple and Android devices. Service availability, features and functionality vary by vehicle, device and the plan you are enrolled in. Terms apply. Device data connection required. Actual images and features may vary and are subject to change. GM Energy PowerShift Charger Installation Manual...
  • Page 50 “Start Upgrade” • Please do not close the app during firmware update(s). These may take up to 15 minutes • Once the update is complete, you should receive a success message GM Energy PowerShift Charger Installation Manual...
  • Page 51 • Current Event: EV0000 is an acceptable event code. If any other event code is present, you can go to “Event History” in the maintenance section of the app to see more details about the error • If you have any questions on how to troubleshoot a fault, please call the GM Energy Customer Support Center at 1-833-64POWER...
  • Page 52 • Attempt to charge the vehicle. Confirm that the EVSE status on the “Device Info” page shows as “Charging” GM Energy PowerShift Charger Installation Manual...
  • Page 53 3. Please enter the serial number of the prior EVSE that has been replaced • The previous EVSE should be uninstalled and the new EVSE should be connected and fully installed before it is ready to be commissioned GM Energy PowerShift Charger Installation Manual...
  • Page 54 *Available on select Apple and Android devices. Service availability, features and functionality vary by vehicle, device and the plan you are enrolled in. Terms apply. Device data connection required. Actual images and features may vary and are subject to change. GM Energy PowerShift Charger Installation Manual...
  • Page 55 7. Check for system firmware updates • Click “Refresh” to search for the most recent firmware updates. Select device(s) requiring updates and click “Start Upgrade” • A confirmation message should pop up once the update is complete GM Energy PowerShift Charger Installation Manual...
  • Page 56 1. Select “Maintenance” to monitor device properties and alter device settings 2. Select “EVSE” if viewing settings for an EVSE-only system 3. Select target device • Ensure the device serial number is displayed correctly GM Energy PowerShift Charger Installation Manual...
  • Page 57 • Connection Status: Monitor the connection status of device and internet − The connected device will display green − The disconnected device will display gray • System Status: Monitor real-time system values of connected devices or any event codes (faults, errors, etc.) GM Energy PowerShift Charger Installation Manual...
  • Page 58 6. Network Setting: • Manage device internet network settings and click “Set” once all settings have been updated 7. Event History: • View the event history by device or event type (fault, error, warning, etc.) GM Energy PowerShift Charger Installation Manual...
  • Page 59 • Click “Refresh” to search for recent firmware versions • Select the device(s) requiring an upgrade and click “Start Upgrade” 9. The update process should take a few minutes. Once complete, the Upgrade Result should read “Update success” GM Energy PowerShift Charger Installation Manual...
  • Page 60 AHJ or other regulatory body. This may require locking out or flipping breakers to the equipment. The installer should communicate with the customer of when the system is approved to operate. To continue on in the GM Energy PowerShift Charger installation process, go to “The GM Energy PowerShift Charger” section.
  • Page 61 Charger...

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