Installation Guide for flo models including: CoRe Plus MAX Level 2 EV Chargers Stations, MAX Level 2 EV Chargers Stations, Level 2 EV Chargers Stations, EV Chargers Stations, Chargers Stations
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DocumentDocumentCoRe+MAXTM
Installation Guide
Table of Contents
1. About CoRe+ MAX ............................................................................................................................ 3 1.1. Canada and USA Electromagnetic Interference Regulatory Statement ........................... 3 1.2. Important Safety Instructions.................................................................................................... 4 1.2.1. Safety Symbols on your Unit................................................................................................. 4 1.2.2. Instructions Pertaining to the Risk of Fire or Electric Shock.......................................... 5 1.2.3. Important General Safety Instructions .............................................................................. 5 1.3. Site Preparation Considerations Prior to Installation............................................................ 7 1.3.1. Rotary Switch Position Table ................................................................................................ 8
2. Communication Gateway ............................................................................................................... 8 3. Installation Instructions ..................................................................................................................9
3.1. Dimensions and Nominal Installation Location.......................................................................9 3.2. Power Cable Installation Under the Station ......................................................................... 10 3.3. Power Cable Installation from the Back .................................................................................. 11
3.3.1. Power Cable Entry on a Station with an Electrical Box or CoRe+ MAX Pedestal ......12 3.3.2. Setting the Current Limit.....................................................................................................13 3.4. Closing the Station Housing .................................................................................................... 15 3.5. Preliminary Tests and Commissioning....................................................................................17 3.5.1. Station Status Light Indicator............................................................................................ 18 4. PowerSharingTM............................................................................................................................... 19 5. Operating Instructions ...................................................................................................................21 6. User Maintenance Instructions...................................................................................................22 7. Moving and Storage Instructions................................................................................................22 8. Specifications ................................................................................................................................. 23 9. Copyright and Liability Information.............................................................................................24
1. About CoRe+ MAX
The CoRe+ MAXTM is part of a family of Level 2 charging stations that are suitable for a wide range of parking layouts, including workplaces, condos, apartments, fleets, and commercial properties. They are ideal for sites where several high-capacity electric vehicles such as commercial service trucks and school buses need to charge simultaneously because the chargers can be cascaded to minimize installation costs for the entire site.
1.1. Canada and USA Electromagnetic Interference Regulatory Statement
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if it is not installed and used in accordance with the instruction manual, it may cause harmful interference to radio communications. Operating this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at their own expense.
This device contains license-exempt transmitters and receivers that comply with Innovation, Science and Economic Development Canada's license-exempt Radio Standards Specifications (RSSs). Operation is subject to the following two conditions:
1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause unwanted operation of the device.
Changes or modifications to this equipment that have not been expressly approved by FLO® may void the user's authority to operate this equipment.
Exposure to radio frequency energy: The radiated power output of the communication modules included in this device is below the limits recommended for the general population for uncontrolled exposure as defined in the FCC standards. This device should be operated with a minimum distance of at least 20 cm (7.87'') between itself and a person's body, and it must not be co-located or operated with any other antenna in order to comply with the conditions of the FCC grants.
1.2. Important Safety Instructions
Read all the instructions before using this product. PLEASE SAVE ALL THE INSTRUCTIONS OF THIS MANUAL.
1.2.1. Safety Symbols on your Unit
Symbol
Alternating current Continuous current
Phase
Description
CAUTION: This symbol is used to provide awareness of important safety information in these instructions
WARNING: This symbol is used to provide warning of hazardous voltage and possibility of electric shock
Earth ``ground'' terminal
Protective (earth) ground Class 1
Chassis
Hot surface
1.2.2. Instructions Pertaining to the Risk of Fire or Electric Shock
This symbol is used to warn you about hazardous voltage and the possibility of electric shock.
When using electrical products, basic precautions should always be followed, including the following. This manual contains important instructions for the CoRe+ MAX model that must be followed during the installation, operation, and maintenance of the unit.
This symbol is used to make you aware of important safety information in these instructions.
1.2.3. Important General Safety Instructions
Always follow the safety instructions below when installing or using the electric vehicle chargers:
Children should be supervised around the device while it is in use. Never insert your finger into the electric vehicle connection. Never use the Electric Vehicle Supply Equipment (EVSE) if the flexible power cord or
Electric Vehicle (EV) cable is frayed, has broken insulation, or shows any other signs of damage. Never use the EVSE if the EV connector enclosure is broken, cracked, open, or shows any other signs of damage. This EVSE was designed to be used with electric vehicles equipped with an SAEJ1772 connector. This EVSE must only be used to charge vehicles that do not require a ventilated environment during charging. Make sure to always disconnect the power supply of the EVSE before servicing it. Avoid installing the EVSE in bad weather conditions.
CAUTION Always use a manual screwdriver. DO NOT use an impact driver for the screws at any time. This will void the warranty.
CAUTION To reduce the risk of fire, only connect to a circuit equipped with appropriate branch circuit overcurrent protection (see the Rotary Position Switch Position Table in section 1.3.1. ) in accordance with the Canadian Electrical Code (CSA C22.1-12) and the National Electrical Code (ANSI/NFPA 70).
1. Handle packaging with care. Always use safety glasses and gloves when unpacking and installing the device.
2. Contact a certified contractor, a certified electrician, or a trained installer to ensure compliance with local building codes, regulations, security standards, and weather conditions.
3. Verify with local authorities that the location where the EVSE is to be installed is free from underground pipelines or electrical equipment; otherwise, you might inflict serious injuries on yourself and others.
4. This EVSE is designed to be wall-mounted or pedestal-mounted.
5. If installed on a wall mount configuration, do not install on or over a combustible surface.
6. Ensure that the types of mounting surfaces of the wall and the posts are strong enough to support more than 56.7 kg (125 lbs.) per anchoring point in the vertical and horizontal direction.
7. Make sure that the anchors are compatible with the type of mounting surface.
8. This product must be connected to a grounded, metal, permanent wiring system. When this is not possible, an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal and installed by a certified electrician.
9. Altering any part of the EVSE will automatically void the warranty.
1.3. Site Preparation Considerations Prior to Installation
Avoid installing the Electric Vehicle Supply Equipment (EVSE) in bad weather conditions.
Split Phase 120/240 VAC supply or single phase 120/208 VAC. Refer to Figure 1 and Figure 2 in the image below.
Both lines must have 120 V between ground. The EV charger must be grounded. The electrical wiring requires 2 lines and 1 ground connection. Neutral is not used.
Refer to Figure 1 and Figure 2. Maximum output power: 19.2 kW @ 240 VAC or 16.6 kW @ 208 VAC. Built-in protection against overvoltage conditions and leakage current to ground. Use 90 °C (194 °F) copper wire conductors only. Field terminals accept wires between 3 AWG and 14 AWG.
1.3.1. Rotary Switch Position Table
Rotary Switch Position
0 1 2 3 4 5 6 7 8 9
Charging Station Current (A)
80 72 64 59 56 48 40 32 24 16
Recommended Circuit
Protection (A) 100 90 80 80 70 60 50 40 30 20
Recommended Wire Gauge (AWG) 3 3 4 4 4 6 6 8 10 14
2. Communication Gateway
Install the Communication Gateway prior to the commissioning of the station. The communication gateway is the property of FLO. Fees will be charged if the gateway is damaged, lost, or not installed according to the installation guide.
Outdoor installation is recommended. The Customer must provide a waterproof PVC box and install it less than 48.7 m (160') from the stations.
Refer to the Communication Gateway Installation Guide for more information. Contact us once the communication gateway has been installed to validate the signal levels and activate commissioning or for any other questions: 1 855 543 8356.
3. Installation Instructions
The CoRe+ MAX can be mounted on a wall or pedestal. Depending on the installation, the power cables can be connected in three different ways (see sections 3.2 to 3.4). If mounted on a CoRe+ MAX pedestal, please refer to the CoRe+ MAX TM Pedestal Installation Guide for the pedestal installation procedure prior to the CoRe+ MAX installation.
3.1. Dimensions and Nominal Installation Location
Back side: 2 matching holes and a rectangular cable opening when pedestal is mounted
Floor
3.2. Power Cable Installation Under the Station
Protection plate
Upper anchor keyhole
Avoid installing the EVSE in bad weather conditions.
Power terminal
B A
Ground terminal
Hole cover
Bottom anchor hole
A
B
Ground Terminal Block
(GND)
Tightening Torque
8 AWG
2,8 N-m [25 lb-in]
10 to 12 AWG 2,3 N-m [20 lb-in]
Power Input Terminal Block
(L1 and L2)
Tightening Torque
3 AWG
4.5 N-m [40 lb-in]
4 to 8 AWG 4.0 N-m [35 lb-in]
10 to 14 AWG 3.0 N-m [27 lb-in]
IMPORTANT The protection plate should always remain over the keyhole.
Follow the steps below to install the power cable under the station:
1. Attach the head base to the wall or post with an anchoring apparatus that can support at least 56.7 kg (125 lbs.) per anchor point (2) in the vertical and horizontal direction.
2. Hang the head base on the upper anchor (previously attached to the wall or post) via the upper anchor keyhole. While doing so, ensure that there is a tight fit and that there is no gap between the gasket and the mounting wall.
3. Complete the mounting of the head base by screwing a mounting bolt through the bottom anchor hole.
4. Remove the hole cover and attach the cable connector to the hole from the bottom, then insert the power cable. Ensure that the conductors are long enough to reach the terminal block. Make sure to seal the cable hole correctly. Ensure that the cable is attached properly by tightening the cable connector (not included). NOTE that the hole is 3.5 cm (1.375").
5. Connect the two power conductors (L1 and L2) and the ground conductor (GND) as indicated with the appropriate tightening torque.
6. The ground conductor must be connected to the terminal ground.
3.3. Power Cable Installation from the Back
Protection plate
Upper anchor keyhole
Avoid installing the EVSE in bad weather conditions.
IMPORTANT: The protection plate should always remain over the keyhole.
Power terminal
1. Attach the head base to the wall or post with an anchoring apparatus that can support at least 56.7 kg (125 lbs.) per anchor point (2) in the vertical and horizontal direction.
B A
Backplate
2. Hang the head base on the upper anchor (previously attached to the wall or post) via the keyhole at the top. While doing so, ensure that there is a tight fit and that there is no gap between the gasket and the mounting wall.
3. Complete the mounting of the head base by screwing a mounting bolt through the bottom anchor hole.
4. Remove the back plate to prevent particle splatter on the equipment.
Ground terminal
Bottom anchor hole
5. Punch a hole of the appropriate diameter in the back plate to install the cable connector. NOTE that the pre-punched hole diameter on the back plate is 34.5 mm (1.36'').
6. Put the back plate back in its place.
A
B
7. Install the cable connector in the hole punched into the back plate, then install the cable. Ensure that the conductors are long enough to reach the terminal block. Make sure that the hole is sealed properly.
Ground Terminal Block
(GND)
Tightening Torque
8 AWG
2,8 N-m [25 lb-in]
10 to 12 AWG 2,3 N-m [20 lb-in]
Power Input Terminal Block
(L1 and L2)
Tightening Torque
3 AWG
4.5 N-m [40 lb-in]
4 to 8 AWG 4.0 N-m [35 lb-in]
10 to 14 AWG 3.0 N-m [27 lb-in]
8. Connect the two power conductors (L1 and L2) and the ground conductor (GND) as indicated with the appropriate tightening torque.
9. The ground conductor must be connected to the terminal ground.
3.3.1. Power Cable Entry on a Station with an Electrical Box or CoRe+ MAX Pedestal
Protection plate
Upper anchor keyhole
Power terminal
Avoid installing the EVSE in bad weather conditions.
IMPORTANT: The protection plate should always remain over the keyhole.
B A
Back plate
Ground terminal
A
Bottom anchor hole
B
Ground Terminal Block
(GND)
Tightening Torque
8 AWG
2.8 N-m [25 lb-in]
10 to 12 AWG 2.3 N-m [20 lb-in]
Power Input Terminal Block
(L1 and L2)
Tightening Torque
3 AWG
4.5 N-m [40 lb-in]
4 to 8 AWG 4.0 N-m [35 lb-in]
10 to 14 AWG 3.0 N-m [27 lb-in]
1. Remove the back plate.
2. Install the head base to align the rectangular opening with the box opening in the wall or post.
3. Attach the head base to the wall or post with an anchoring apparatus that can support at least 56.7 kg (125 lbs.) per anchor point (2) in the vertical and horizontal directions.
4. Hang the head base on the upper anchor (previously attached to the wall or post) via the keyhole at the top. While doing so, ensure that there is a tight fit and that there is no gap between the gasket and the mounting wall.
5. Complete the mounting of the head base by screwing a mounting bolt through the bottom anchor hole.
6. Make sure that the opening between the charging station and the electrical box or pedestal is properly sealed.
7. Connect the two power conductors (L1 and L2) and the ground conductor (GND) as indicated with the appropriate tightening torque.
8. The ground conductor must be connected to the terminal ground.
3.3.2. Setting the Current Limit
By default, the CoRe+ MAX is set to maximum power in the factory. If your electrical infrastructure does not allow the charging station to operate at maximum power, it can be reduced using the Current Limiter Switch.
WARNING Make sure that the power is off.
Follow the steps below to set the current on the charging station: 1. Locate the Current Limiter Switch on the main Printed Circuit (PC) board.
2. Using a flat-head screwdriver, gently rotate the switch to the desired position. Refer to the following table to determine the rotary switch position:
Rotary Switch Position 0 1 2 3 4 5 6 7 8 9
Charging Station Current (A) 80 72 64 59 56 48 40 32 24 16
3. Detach the corresponding maximum current setting label sticker from the label set kit that comes with the unit. Stick it over the existing label on the charging station enclosure to inform the maintenance personnel of the maximum current setting. Proof of installation will be required to complete the commissioning to ensure that the label corresponds to the installation. This is important for safety and warranty validity considerations.
3.4. Closing the Station Housing
1. Ensure that the gasket on the lip shown below is properly aligned.
Gasket
2. Connect the data cable to its respective connector as shown below. WARNING: NEVER CONNECT/DISCONNECT THE DATA CABLE WHEN THE CHARGING STATION IS ENERGIZED. THIS COULD DAMAGE THE UNIT.
Groove
3. Align the housing groove to the charging station lip and push the housing toward the charging station, ensuring that the gasket stays in place.
Lip gasket
4. Apply slight pressure to the front cover, then screw on the top 2 bolts, ensuring that the O-rings stay on the screws. Screw on the bottom 2 bolts. Tighten all screws to 30 lb-in (3.4 N-m). WARNING: NEVER USE AN IMPACT DRIVER TO AVOID DAMAGING THE THREADS!
5. Place the charging cable on the cable holder and the charging connector in the receptacle.
3.5. Preliminary Tests and Commissioning
Follow the steps below to complete the preliminary tests and commissioning: 1. Turn on the power to the charging station. You should be able to observe the following results immediately after the power is turned on: a. The status light is on continuously; its color is green. b. The greeting message is displayed. NOTE: If no message appears, ensure that the data cable is connected by following step 2 in section 3.4. 3.4. while the station is NOT energized. 2. Scan the access card provided with the charging head. You should be able to observe the following results: a. Once the reader detects the card, it will emit an audible beep.
b. Immediately after the beep, the access card will be authenticated by the charging station.
c. If the authentication of the card is successful, the automated test of the protection circuit will be performed.
d. Once the test is successfully completed, the overhead status light will start flashing (white).
e. If the connector is inserted into an electrical vehicle, it will begin charging. If it does not begin charging after 1 minute, the charging station is in wait mode.
3. Once the charging station successfully passes the preliminary test, the charging station can be used as a private charging station (using the provided access cards) or be connected to FLO's management system by turning on the communication gateway provided by FLO. Call FLO Services at the number provided on the sticker in front of the charging station to process the commissioning step. If the commissioning is not completed, the station will be limited to 6 A when manufactured in PowerSharingTM mode.
3.5.1. Station Status Light Indicator
Color Green - Solid color
White - Blinking
Blue - Solid color Red - Solid color Off
Meaning The charging station is ready for session activation. Session authenticated; the charging station is ready to plug into the electric vehicle (EV). The charging station is plugged in, and energy is being delivered. Critical fault
Out of service
4. PowerSharingTM
The CoRe+ MAX can be configured in standard or PowerSharing mode. With the integrated PowerSharing capability of the CoRe+ MAX, a maximum of four charging stations sharing the same 100 A circuit for a total load of 80 A can be connected in parallel to the same branch circuit. Here are some characteristics of PowerSharing mode:
The charging stations connected in parallel to the same branch circuit must all be CoRe+ MAX models (the specific model identification can be found on the unit label).
To allow for dynamic current sharing, a site controller application must be installed and properly configured by FLO.
Without a site controller installed or in operation, or in the event of a loss of communication, each CoRe+ MAX limits its output to 6 A when set in PowerSharing mode.
The site controller will then ensure that the maximum available current is shared optimally among the charging stations (between 6 A and 80 A for each station) while ensuring that the maximum circuit capacity (80 A in the case of a circuit protected by a 100 A breaker) is never exceeded.
For safety reasons, each CoRe+ MAX charging station will immediately interrupt an ongoing charging session when the connected EV draws more than the specified amperage limit at any time. To resume charging, the user must restart the usage session process from the beginning.
The site controller is provided by FLO as part of its Global Management Service (GMS).
The communication between the site controller and the charging station is done through a wireless meshed Zigbee network. A communication gateway must therefore be installed. Refer to the Communication Gateway Installation Guide provided by FLO for further details.
The maximum number of charging stations sharing the same 100 A circuit (for a total load of 80 A) is 4.
Typical Installation
208 or 240 V @ 100 A circuit1
Junction boxes allowing the charging stations to be connected in parallel to the same branch circuit
NOTE: Ensure that the electrical wiring and the associated electrical hardware used to connect the charging stations in parallel comply with the local regulations in place.
5. Operating Instructions
1. Activate the station: Place your card on the reader OR select the station in the mobile app and press "Start a session."
2. Pick up the connector and unwind the cable to the required length.
3. Plug the connector into your vehicle. The charging will start immediately.
4. Once the charging is complete, put the connector back in its socket.
WARNING: Once the charging is complete, make sure to wind the cable back up and store the connector in its socket.
6. User Maintenance Instructions
The CoRe+ MAX enclosure is Type 3R, which is intended for indoor or outdoor use and provides a degree of protection against corrosion, windblown dust, rain, splashing water, and hose-directed water. It is designed to remain undamaged by ice, which can form on the enclosure.
This enclosure type ensures that the maintenance required to protect the integrity of the charging station enclosure is minimal, except for cleaning, which can be performed with standard domestic products recommended according to the type of dirt.
When not in use, the charging cable should be properly wound around the holder on the station enclosure, and the cable connector should be always inserted into its enclosure. Do not twist, bend, or pull on the cable from the connector alone, either to wind it around the enclosure or when it is stuck.
When handling the cable, please ensure that the cable's outer insulation and the connector itself do not show any excessive signs of wear, such as cracks or abrasion. If there is any damage, please call the Installation or Commissioning Questions number at the end of this manual for reporting and case management purposes.
7. Moving and Storage Instructions
The charging station is designed to remain in a fixed position and is not intended to be portable.
Prior to installation, we recommend that the station be kept in its shipping packaging at temperatures between -40 °C and 50 °C (-40 °F to 112 °F) and at a humidity level not exceeding 95% (non-condensing) until it has been installed by qualified personnel.
8. Specifications
Specification Description of the charger Output connector Input connector
Maximum output power Operating temperature range Built-in protection Enclosure Shipping weight Communication protocols
Security standard certification
Energy certification
Description Level 2, 80 A charging station equipped with display and card reader Output connector: J1772-compliant Split Phase 120/240 VAC supply or single phase 120/208 VAC (refer to Figure 1 and Figure 2) Maximum configurable output power: 19.2 kW @ 240V or 16.64 kW @ 208V Operating temperature range: -40 °C to 50 °C (-40 °F to 122 °F) Overvoltage conditions and leakage current to ground 3R-type enclosure; suitable for outdoor use Approximately 12.15 kg (27 lbs.) OCPP version 1.6J EMI compliance: USA - FCC 47 CFR part 15 class A CAN - ICES-003 (A)
CSA- C22.2 No. 280 / UL 2594, CSA C22.2 No. 281.1 and 281.2 / UL 2231-1 and 2231-2
ENERGY STAR® 1.2
9. Copyright and Liability Information
Name: FLO_CoRe+ MAX_Installation Guide_V.4.0.1_2024-09-23_CA_EN Document ID: PRFM0042
FLO CA: © 2022-2024 Services FLO Inc. All rights reserved. FLO, the FLO logo, LEAD THE WAY, and TRACEZ LA VOIE are trademarks of Services FLO Inc. ADDÉNERGIE is a trademark of AddÉnergie Technologies Inc. used under license by Services FLO Inc.
This document is provided as a general instruction guide. All pictures shown are for illustrative purposes only. Actual stations may vary in size or due to product enhancements, in which case additional steps may be required. AddÉnergie Technologies Inc. and its subsidiaries ("AddÉnergie") reserve the right to alter this document and any product offerings and specifications at any time without notice, and AddÉnergie does not guarantee that this version of the document is current. It is your responsibility to comply with all applicable laws, including those related to accessibility and zoning, and to exercise due diligence when performing an installation or using this product. Careless installation or misuse may result in injury or product damage. To the fullest extent permitted by applicable laws, AddÉnergie disclaims any liability for personal injury or property damage resulting from the installation or use of this product.
Contact us 1 855 543-8356 info@flo.com flo.com
Eastern office: 2800, Louis-Lumière Street, office 100, Québec (QC) G1P 0A4 CANADA Regional office Western Canada: #501 4190 Lougheed Highway Burnaby (British Columbia), Canada, V5C 6A8 United-States Office: 1270 Pacific Dr, Auburn Hills, MI, United States 48326
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