GM PowerUp Manual

BEFORE INSTALLATION

Accessory Kit

Recommended Tools
The following tools are recommended for the PowerUp charger installation:

• Electric screwdriver
• Power drill
• T20 Torx driver bit
• T25 Torx driver bit
• Hex driver bit
• Phillips head driver bit
• Step drill bit, i.e. 1-1/8"
• 6mm drill bit
• Vacuum
• Rectangular file
• Torque wrench
• Level
• Tape
• Marker

Installer-supplied Components
The installers should prepare the following parts for the PowerUp charger installation:

1. Conduit of appropriate size for input power wires to ensure water resistance.
2. Conduit fitting(s) for input power wires to ensure water resistance.
3. Upstream breakers:
   To reduce the risk of fire, only connect to a circuit with 60 amperes maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70, and the Canadian Electrical Code, Part 1, C22.1.

THE POWERUP CHARGER

LED Indicator Definitions

INSTALLING THE POWERUP CHARGER

Before you start, please read the following instructions:

Selecting the Installation Site
The PowerUp charger can be installed in both indoor and outdoor environments. It is necessary to consider the installation conditions and protection at the site:

• Follow local electrical regulation and installation standards.
• Consider the emergency routes at the installation site.
• Do not install the device in areas with explosive gases or vapors.
• It is recommended to install the PowerUp charger in a location that avoids direct sunlight.
• Install the PowerUp charger on a non-flammable support that is suitable to handle the weight of the unit.
• Ensure the ambient temperature of the location is between -40°F and 122°F (-40°C — 50°C).

Recommended Installation Positions
When considering installation positions, make sure the PowerUp charger can be easily connected with the PowerUp charger and have enough space for maintenance.

1. Recommended position
2. Alternative position

Recommended Installation Space
Installers should follow applicable accessibility requirements when selecting the mounting position. The PowerUp charger should be mounted at a height between 600 mm (24 inches) and 1.2 m (47.2 inches) above ground.

Preparation
After removing the PowerUp charger and the accessories kit from the packaging, you must first create an opening to allow you to route the AC power wires into the system:

1. Remove the cosmetic cover.
   1. Remove the single T20 Torx screw from the bottom.
   2. Pry open the bottom of the cosmetic cover.
   3. Remove the cosmetic cover from the unit.
      
2. Remove the middle cover.
   1. Remove the eight T20 Torx screws from the sides of the middle cover and the center of the plug holder.
   2. Remove the middle cover from the unit.
      
3. Routing the AC power wires is possible through the bottom or rear of the enclosure. Using the power drill and 1-1/8" step drill bit, drill an opening for the wires from the outside of the unit based on how the power wires need to be fed into the unit (i.e., the bottom or rear).
   
4. Use the vacuum to clean up any debris left from the drilling process.

Wall Mounting
The unit must be mounted on one of the following types of (solid) walls only:

• Non-cracked concrete or solid brick: Use the three 1/4" concrete anchor screws provided to secure the PowerUp charger unit onto the wall.
• Solid wood or drywall and solid wood (wall stud): Use the three 5.5 mm wood screws provided to secure the PowerUp charger unit onto the wall.

1. Use the template and level to mark out the position of the three screws that will be used to secure the wall mounting bracket and unit to the wall.
   
2. Use the power drill to drill the three pilot holes marked in the previous step.
3. Use two of the wall screws to mount the bracket onto the wall so that the hooks on the bracket protrude outwards.
   Note:
   A single wall screw installed on the right side of the mount is required, but installing both screws is recommended.
   
4. Place the unit on the bracket by aligning the slots on the rear of the chassis to the corresponding hooks on the bracket.
   
5. Use the remaining screw to secure the unit to the wall.
   

Once you have mounted the unit onto the wall you can proceed with connecting the power wires.

Making the Connections


BEFORE CONNECTING THE AC POWER WIRES TO THE UNIT, ENSURE THAT UPSTREAM BREAKER HAS BEEN USED TO DE-ENERGIZE THE CIRCUIT.

1. Strip the wires at a length of 10 – 11mm.
2. Thread the AC power wires through the conduit and conduit fitting. Ensure 6 inches of free wire
3. Install the conduit assembly onto the unit.
   Note:
   For the torque to use when installing the conduit assembly, please refer to the recommended values listed in the specifications.
4. Connect the AC power wires.
   1. Insert the corresponding wires into the input terminals marked "PE", "L2", and "L1".
   2. Torque each terminal with a Phillips-head screwdriver (torque: 19 ± 2 in-lbs / 2.2 ± 0.2 Nm).
      Note:
      Use 90°C copper conductors only for the AC power wires.

Once you have connected the power wires you can proceed with configuring the DIP switches.

CONFIGURING THE DIP SWITCHES

The factory default output is 0A for the PowerUp charger. Use the DIP switches to configure the maximum output current ratings.

The following settings can be configured with the DIP switches:

Maximum Current Settings
Pins 3 to 5 configure the maximum output current ratings.

DIP Switch Setting	Configuration	PowerUp AC Amperage	OCPD Breaker Size
00000		0	N/A
00100		20	25
00010		24	30
00110		28	35
00001		32	40
00101		36	45
00011		40	50
00111		48	60

Refer to the following steps to setup the DIP switches during the initial installation.

1. Open the middle cover and locate the DIP switch. The default setting should be 00000.
   
2. Change the DIP switch to the desired output current based on pin configuration table (the example below is for a 40A output current).
   
3. Place the middle and cosmetic cover back onto the PowerUp charger. See "Completing the Installation".
4. Turn on the breaker to power on the PowerUp charger. When the LED is solid. The installer can use the commissioning app to confirm whether the DIP switch setting has been completed.

Refer to the following steps if the output current has already been set using the DIP switches and you want to change the output current.

1. Turn off the breaker to ensure that the customer does not open the cover with the power on.
2. Open the cosmetic and middle cover.
3. Change the DIP switch to the original factory settings (i.e., 00000).
   
4. Reinstall the middle cover, then power on the PowerUp charger until the LED lights up solid red, white, and green (all on).
5. Turn off the breaker to power off the PowerUp charger.
6. Refer to the steps in the previous section (DIP switch configuration for initial installation).

Completing the Installation
Once you have finished configuring the DIP switches, double-check that all the prior instructions have been followed correctly, and then proceed with the steps below to complete the installation:

1. Put the middle cover back and fasten the eight screws securely (torque: 10.5 ± 0.9 in-lbs / 1.2 ± 0.1 Nm).
   
2. Install the cosmetic cover onto the system so that the hooks on the top side are inserted into the corresponding notches on the system first, then push the cover into place, and fasten the single screw securely (torque: 10.5 ± 0.9 in-lbs / 1.2 ± 0.1 Nm).
   
3. Place the charging cable and coupler onto the plug holder properly.
   
4. Power the unit by switching on the breaker, then verify that the LED lights up solid white indicating that the PowerUp installation is complete.
   Note:
   • If the LED displays a red, white, and green solid pattern, it indicates the DIP switch setting is not complete.
5. To complete the PowerUp charger setup, follow the steps below to connect your charger to Wi-Fi and the app on your mobile device.

Wi-Fi and Mobile App Setup
If you haven't already, download your vehicle's mobile app (myChevrolet, my Buick, myGMC, or myCadillac) and log in to the system using your vehicle account credentials.

1. On your home screen tap Add Product.
2. Choose Charger from the list of products.
3. Select Your Charger Model ("PowerUp 2") from the list of chargers.
4. The app will then take you through the setup steps to successfully connect your charger to your local Wi-Fi router.
   For any issues with charger setup please call our Support Center at 1-833-64POWER.

MAINTENANCE

Annual Requirements

1. Conduct a visual inspection of the charging cable and ensure that cable does not show any visual damage or deformation.
2. Conduct a visual inspection of the charging coupler and ensure that coupler does not show any visual damage, arcing or rust.

To avoid danger of electrical shock or injury, turn off power at the panel board or load center before working on the equipment or removing any component. Do not remove circuit protective devices or any other component until the power is turned off.
Disconnect electrical power to the EV charging solution before any maintenance work to ensure that it is separated from the supply of AC mains. Failure to do so may cause physical injury or damage to the electrical system and charging unit.
Note:

• Touching the circuit before the main breaker and auxiliary breaker are switched off may be hazardous. The switching device and other apparatus can only be inspected visually.
• Maintenance of the EV charging solution shall be conducted only by a qualified technician.
• After opening the front door, turn off the main breaker and auxiliary breaker before any maintenance work.

Cleaning
Regular cleaning of PowerUp Charger is recommended. During charger stand-by state, use a soft lightly-dampened cloth with clear water to remove any dirt, ensure that no water enters the charging coupler.

SPECIFICATIONS

TROUBLESHOOTING

• Contact customer support if the PowerUp charger appears to malfunction or if the LED indicators display an error.
• Plese refer to "LED Indicator Definitions" for LED indicator definitions.
• DO NOT open the PowerUp charger, touch or remove the circuit protective devices or any other component.

ERROR CODES