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User Guide
Portable EV CHarger
TurboCord 240V
English
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© 2013-2018 Webasto Charging Systems, Inc. All right s reser ved.
Webasto, E V Soluti ons, and the Webasto logo are trademarks of Webasto Charging Systems, Inc.
Corporate na mes, trad emarks, registe red trade marks, s ervice marks, s ymbols, and logos stated herein are property of their
respective companies.
Specifications are subjec t to change without n otice. Images of the Dual voltag e charger are representative; production mode ls may
vary. Dual vo ltage charger may be branded un der different names.
No portion of the se materials may be duplicated, used or disclosed without prior writ ten permission from Webasto Cha rging
Systems, Inc.
Disclaim er: This us er guide includes th e latest information available at the time of printing. Webasto Charging Systems, Inc. reserves
the right to ma ke changes to this user gui de and/o r produc t withou t furthe r notice. Chang es or modi fications to this pro duct not
complete d by an authorized ser vice provider could void the product warranty.
Corporate Headquarters
Webasto Charging Systems, Inc.
EV Solutions™
800 Royal Oaks Drive, Suite 210
Monr ovia , CA 91016 -6347
Phone: 626 -357-9983 or 888-833-2148
Fax: 626-359-9628
Email: evscs@ webasto.com
Website: www.evsolutions.com
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with the E xpor t Administration Re gulations. Diver sion contrary to US law is prohibited.
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OWNER’S RECORD
model:
TurboCord Charger
serial number (s/n):
purchase date:
A NOTE ON CUSTOMER SUPPORT
To ensure superior service, please take note of your serial number when contacting
customer support.
Write down the serial number of your charger in the “Owner’s Record” above. The serial
number can be found on the bottom of the charger’s plug-in module.
Webasto Charging Systems
Customer Support
1-888-833-2148
evscs@webasto.com
22600-03 Rev.03
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with the E xpor t Administration Re gulations. Diver sion contrary to US law is prohibited.
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SAVE THESE INSTRUCTIONS!
This manual contains important instructions for the TurboCord charger that
shall be followed during installation, operation and maintenance of the unit.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION ...................................................................................... 1
Symbol Usage ....................................................................................................... 2
About Your TurboCord Charger ............................................................................ 3
TurboCord Charger Components .......................................................................... 5
Required Outlets ................................................................................................... 6
SECTION 2: USING YOUR TURBOCORD CHARGER ................................................ 7
Know Your Indicator Lights ................................................................................... 8
Charging Your Vehicle .......................................................................................... 9
Manual Stop ........................................................................................................10
A Note on Auto-Restart .......................................................................................10
SECTION 3: TROUBLESHOOTING ............................................................................ 11
APPENDIX .................................................................................................................. 14
Specifications .......................................................................................................15
Installing the Cable Hanger ..................................................................................16
High Voltage Warning .........................................................................................17
State of California Proposition 65 Warnings ........................................................18
FCC Information ..................................................................................................18
Safety Features ....................................................................................................18
Limited Warranty ................................................................................................ 20
Index ...................................................................................................................21
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Section 1
INTRODUCTION
Page 6
SYMBOL USAGE
DANGER
WARNING
NOTE
Indicates information about safety practices which, if not
followed, may result in serious injury or death.
.......................................................................................
Indicates information about safety practices which, if not
followed, could result in personal injury or are necessary to
prevent fire or equipment overheating.
.......................................................................................
Indicates helpful information for installation or usage, but
does not contain personnel or equipment safety related
information.
2
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ABOUT YOUR TURBOCORD CHARGER
Thank you for purchasing the TurboCord Charger – our easy-to-use, compact, and
portable power supply for your electric vehicle’s on-board charger. The charger supplies
and manages AC power to your electric vehicle and is compatible with a variety of battery
electric and plug-in hybrid electric vehicles.
The charger operates from a 208/240 VAC 60 hertz power source.
Key Features
• Compact, portable design
• Overheating protection
• Quick-read status indicators
• Underwriters Laboratories (UL) listed
• SAE J1772 compliant
• Auto-restart in the event of ground fault or power outage
240VAC Operation: the charger requires either a 240 VAC split phase or a 208 VAC two
phase dedicated circuit. It draws a maximum of 16 amps continuous current and requires a
20 amps rated circuit breaker.
This product must be grounded. If it should malfunction or
break down, grounding provides a path of least resistance
WARNING
for electric current to reduce the risk of electric shock.
This product is equipped with a cord having an equipment
grounding conductor and a grounding plug. The plug
must be inserted into an appropriate outlet that is properly
installed and grounded in accordance with all local codes
and ordinances.
Improper connection of the electrical outlet grounding
conductor might result in a risk of electric shock. Check with
WARNING
a qualified electrician if you are uncertain whether or not
the electrical outlet is properly grounded. Do not modify the
plug provided with the product if it does not fit in the outlet.
Have a proper outlet installed by a qualified electrician.
It is recommended that electrical outlets for use with your
WARNING
charger be installed by a licensed, qualified electrician. To
avoid serious injury or death, installation must comply with
the provisions of the National Electric Code (NEC) and all
local codes. In cases of conflict between local codes and the
NEC, local codes shall take precedence.
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WARNING
DANGER
WARNING
NOTE
Do NOT DROP charger or coupler.
.......................................................................................
If the output cable becomes separated from the charger
module or the charge coupler, DO NOT ATTEMPT TO REPAIR
THE CABLE YOURSELF. Contact AV Customer Support for
assistance.
.......................................................................................
When using your charger, basic precautions should always be
followed, including the following:
• See warnings on charger cord label. Read warnings before
operating the unit the first time. Read all instructions in this
guide before using this product.
• Never use the charger with an extension cord.
• Never use the charger with any AC adapter.
• Shock hazard – make sure the plug is fully inserted into the
wall outlet so that there are no exposed blade surfaces.
• Children should be supervised when in the vicinity of the
charger while plugged in.
• Do not put fingers into the electric charge coupler.
• To reduce the risk of fire, connect only to a circuit provided
with 20 amps maximum branch circuit overcurrent
protection.
• Do not use in a commercial garage classified for internal
combustion engine vehicles due to vapors of flammable
liquids (gasoline) being present.
.......................................................................................
TurboCord will not charge and will give a fault indication if
ground is not present.
4
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Page 9
TURBOCORD CHARGER COMPONENTS
Charge Module
Release button
Charger Coupler
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REQUIRED OUTLETS
NOTE
Any electrical socket should be checked by an electrician.
208/240VAC operation: a NEMA 6-20R wall outlet is required.
NEMA 6-20R wall receptacle
240V
NOTE
A dedicated 240 VAC split phase circuit or a 208 VAC two
phase circuit and a 20 amp rated circuit breaker are required.
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SECTION 2
USING YOUR
TURBOCORD CHARGER
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KNOW YOUR INDICATOR LIGHTS
The Indicator light on your charger is the first thing you will notice when you
are about to plug or unplug your vehicle. Before we get started, here is a simple
explanation of the indicators.
CHARGE MODULE INDICATOR LIGHTS
Red TROUBLE
Indicator light
Blue STATUS
Indicator light
BLUE: STATUS
When plugged into the wall outlet, the BLUE STATUS Indicator illuminates to
communicate that the charger is ready to use.
RED: TROUBLE
The RED TROUBLE Indicator illuminates when the charger has detected an error. If
the RED TROUBLE Indicator is illuminated, the charger will not deliver power to the
vehicle. The error must be corrected before a charging cycle can begin or continue.
Refer to the Troubleshooting Guide in Section 3 for more information.
NOTE
WARNING
8
A momentary blink of the RED TROUBLE indicator at first
plug-in to the wall socket is normal and functions as a
startup safety check. This momentary blink is followed by
the solid BLUE STATUS Indicator and the RED TROUBLE
indicator turns off.
.......................................................................................
A constant or blinking RED TROUBLE Indicator indicates an
actual problem.
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CHARGING YOUR VEHICLE
Your charger is designed for easy charging in 240 VAC.
1. Make sure the car is in park and turned OFF.
2. Insert charger into appropriate wall outlet.
3. RED TROUBLE light will flash briefly, then turn off; BLUE STATUS Indicator
light will stay solid indicating that charger is receiving AC power and is ready to
charge.
4. Plug the CHARGE COUPLER into your vehicle’s charging outlet until it clicks.
Once latched, the CHARGE COUPLER will not disengage unless the release
button is pressed manually.
5. Automatic charge begins. Power will be delivered in accordance with vehicle
demand. If the vehicle is charging, the BLUE STATUS Indicator will blink on and
off approximately every two seconds. Always verify that the vehicle charging
status indicator agrees.
6. When fully charged, the BLUE STATUS Indicator light illuminates solid blue.
Your vehicle has a “dashboard gauge” that can verify the vehicle is fully
charged. Refer to the vehicle owner’s manual to find the gauge location on
your dashboard.
7. Disconnect when the charge is complete by pressing the release button on the
CHARGE COUPLER and removing it from the vehicle.
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When plugging into an unfamiliar wall outlet, it is good
practice to let the vehicle charge for several minutes before
NOTE
leaving it unattended to ensure it is in fact supplying the
expected AC charging power.
The RED TROUBLE Indicator will illuminate if not charging.
The unit will turn OFF if breaker or infrastructure GFI is
tripped.
MANUAL STOP
To safely stop charging at any time before charge completion, press the CHARGE
COUPLER release button and remove it from the vehicle.
Charging will automatically and safely stop.
BLUE STATUS Indicator remains ON solid.
A NOTE ON AUTO-RESTART
The Auto-Restart feature helps ensure that your vehicle will be charged and ready
for use when needed. A charge may be interrupted if an error is detected. Charging
will resume once the error is no longer detected. The RED TROUBLE Indicator
illuminates during an error condition.
The exception to immediate Auto-Restart is when the interruption is due to a
charger GFCI event. The charger will attempt to restart 15 minutes after a GFCI
event. After the fourth attempt to restart, the charger will shut down and the RED
TROUBLE Indicator will stay ON.
If the fault persists, do not continue to try to charge your vehicle. Contact AV
Customer Support.
10
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CHAPTER 3
TROUBLESHOOTING
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TROUBLESHOOTING
Please refer to this Troubleshooting Guide for possible solutions to common errors
or difficulties with charging your vehicle using your portable charger.
NOTE
There are no user serviceable parts inside.
A RED TROUBLE Indicator may be triggered by several sources, including the
charger, the utility service, or the vehicle. See Troubleshooting tips below.
The RED TROUBLE Indicator turns on when the charger detects an error whether it
is connected to your vehicle or not. With the RED TROUBLE Indicator on, the dual
charger will not deliver power to the vehicle. The error must be corrected before
charging begins or resumes.
Problem Possible Cause Solution
Do not attempt to repair or service the charger yourself.
BLUE STATUS
Indicator does not
illuminate
No power to unit 1. Check circuit breaker and other
circuit loads.
2. Try another wall outlet.
3. Ensure charger module (and
adapter if operating in 240VAC
mode) is fully inserted into the
wall outlet.
Vehicle will not
charge
BLUE STATUS
Indicator remains
solid
Charger internal
failure
Charge coupler is
not inserted into
the vehicle
Vehicle is not in a
state to accept a
charge
Contact Customer Support for
assistance.
1. Inspect the charge coupler.
2. Remove the charge coupler from
the vehicle, then reinsert it into
the vehicle receptacle until it
clicks.
Verify vehicle charge timer is set to
permit charging. Refer to the vehicle
owner’s manual for charge timer
instructions.
Communication
error between
Contact Customer Support for
assistance.
charger and vehicle
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Page 17
Problem Possible Cause Solution
RED TROUBLE
Indicator is blinking
rapidly
Utility fault 1. Disconnect the charger module from
the wall outlet, then reconnect to the
wall outlet.
2. If the condition persists, have a
qualified electrician inspect the wall
outlet ground circuit integrity.
3. Repair as required.
Above temperature
limit
Cases:
• Temperature is
too high. The
1. Inspect charger module for overheating
(hot to the touch).
2. Carefully unplug charger module from
the wall outlet and allow to cool.
3. If the condition persists, contact
Customer Support for assistance.
charger will
4. Disconnect the charger (and adapter, if
operating in 240 VAC mode) from the
wall outlet.
5. Have a qualified electrician inspect the
wall outlet and adapter integrity.
6. Repair as required.
RED TROUBLE
restart charging
when it cools
down.
• House/socket
wiring may be
faulty.
Vehicle problem Contact your vehicle service department.
Indicator is on solid
when connected to
vehicle
RED TROUBLE
Indicator is off
and BLUE STATUS
Indicator is on when
you unplug from
vehicle
RED TROUBLE
Indicator is on solid
NOT connected to
vehicle
RED TROUBLE
Indicator and BLUE
STATUS Indicator are
both on
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Charger internal
failure
Charger trying to
resolve internal
error
Contact Customer Support for assistance.
Charger will return to normal operation
within 1 minute. If problem persists,
contact Customer Support for assistance.
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APPENDIX
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SPECIFICATIONS
Model TurboCord Charger
Line input power: 240/ 20 8 VAC
Output power: 16 amps continuous @ 240/208 VAC
Circuit breaker rating: 20 amps @ 240 VAC
Frequency: 60 Hz
Power draw at idle
during charging:
< 2 watts
< 4 watts
Cable length: approximately 20 ft. (6.1 m)
Weight: 4 lb. (1.81 kg) - module
Temperature –
operating:
Temperature –
storing and transporting:
-40°C to +50°C (-40°F to 122°F)
-40°C to +70°C (-40°F to +140°F)
Environmental rating: NEMA 6P (watertight)
Vehicle – charger communication
protocol:
SAE J1772 compliant
Charge coupler: SAE J1772 compliant
Direction of charge: Grid to vehicle
Specifications are subject to change without notice.
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INSTALLING THE CABLE HANGER
CABLE HANGER MOUNTING INSTRUCTION
1. Choose a location to install the cable hanger.
• The hanger should be located in practical proximity to both the utility
service and the location of your vehicle’s charge receptacle. Preferably
mounted to a wall stud. Drywall and masonry wall installations require the
use of appropriate inserts.
2. Measure up approximately 36” from the floor and mark the location.
3. Drill out the preferred mounting holes through the back of the cable hanger
using a 7/32-inch drill bit.
4. Using a Phillips screwdriver, tighten the screws for the cable hanger.
16
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Page 21
HIGH VOLTAGE WARNING
High voltage is present in your electric meter housing and
DANGER
WARNING
WARNING
WARNING
NOTE
power distribution service panel. Contact with high voltage
can cause death or serious personal injury.
.......................................................................................
DO NOT operate your charger with a damaged output cable,
charge coupler, or module. Visually inspect the output cable,
charge coupler, and charger module for damage before each
use. If you detect any damage, stop using the charger and
contact Customer Support.
.......................................................................................
ALWAYS position the charger output cable so that it will
not be driven over, stepped on, tripped over, or otherwise
damaged or stressed. To prevent personal injury and damage
to the charger, ALWAYS stow the charger on hanger or in
stowage bag after use.
.......................................................................................
Use the charger only to supply power to electric vehicles
equipped with an SAE J1772 compliant vehicle receptacle.
For more information, refer to the vehicle owner’s manual.
.......................................................................................
Disconnect the charger from the wall outlet before cleaning
it. To clean the charger, wipe it with a clean cloth dampened
with water or a mild detergent solution suitable for use on
automobile paint. Do not use chemicals or solvents. Do not
submerge the charger.
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STATE OF CALIFORNIA PROPOSITION 65 WARNINGS
WARNING
This product contains a chemical known to the State
of California to cause cancer or birth defects or other
reproductive harm.
FCC INFORMATION
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
• This device may not cause harmful interference.
• This device must accept any interference received, including interference that
may cause undesired operation.
This product has been designed to protect against Radio Frequency Interference
(RFI). However, there are some instances where high-powered radio signals or
nearby RF-producing equipment (i.e. digital phones, RF communications equipment,
etc.) could affect operation.
If you suspect your charger is receiving interference, take the following steps before
contacting Customer Support for service:
1. Relocate nearby electrical appliances or equipment during charging.
2. Turn off nearby electrical appliances or equipment during charging.
Important! Changes or modifications to this product by anyone other than an
authorized service provider will void FCC compliance.
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SAFETY FEATURES
The charger is designed with your safety as the highest priority and includes the
following safety features to protect against the risk of electric shock:
• Service Ground Check: The charger constantly checks for the presence of a
service ground connection. If the service ground ever fails, the charger RED
TROUBLE Indicator turns ON and shuts down power to the vehicle.
• Thermal Event Sensor: Charger module senses out-of-ordinary thermal events
and will shut the unit down.
• GFCI Protection: The charger is equipped with a Ground Fault Circuit
Interruption (GFCI) reaction system to protect against electric shock. If the
charger module detects an output ground fault, it will shut down power to the
output cable and illuminate the RED TROUBLE Indicator.
• Insulation: The charger module, adapter, cable assembly and charge coupler
are completely insulated (no exposed live parts) to protect against electric
shock.
• Unintentional Disconnection: The charge coupler is designed to minimize
unintentional disconnection. A pilot signal wire in the cable and charge coupler
eliminates the possibility of electric shock when not connected to a vehicle
or if an unintended disconnect occurs during a charge. Disconnection during
charging is safe.
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LIMITED WARRANTY
TURBOCORD CHARGER LIMITED WARRANTY
KEEP RECEIPT FOR WARRANTY CLAIMS.
The Webasto Charging Systems, Inc. TurboCord EV charger is warranted to be free
of defects in material and workmanship for a period of thirty-six (36) months from
the date of original purchase.
THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY WEBASTO WITH
RESPECT TO THE TURBOCORD CHARGER. OTHER THAN EXPRESSED AND/
OR IMPLIED WARRANTIES REQUIRED BY APPLICABLE LAWS OR WHICH ARE
REQUIRED TO EXTEND FOR A LONGER PERIOD, THERE ARE NO WARRANTIES THAT
EXTEND BEYOND THIS LIMITED WARRANTY AND ANY REQUIRED WARRANTIES
ARE LIMITED IN DURATION TO THE WARRANTY PERIOD.
To the extent permitted by applicable laws: (a) Webasto’s total warranty expense
with respect to the charger is limited to a maximum of the original purchase price
of the charger as applicable to a warranty claim; (b) Webasto’s liability under
this warranty shall be limited to the repair or replacement, at Webasto’s option,
of defective component parts; and (c) Webasto will not be liable for repair,
replacement or service call costs for the charger not covered by this warranty, which
shall be the responsibility of the purchaser.
This warranty shall be voided by damage or excessive wear to the charger caused
by abnormal operating or environmental conditions (including exposure to acid,
chemical fumes, metallic dust or extreme temperatures), accident, abuse, damage,
misuse, vandalism, unauthorized alteration or repair, utility surges, or if the charger
was not operated, serviced or maintained in strict compliance with the charger
User’s Manual and other printed instructions provided by Webasto and applicable
building codes. Any evidence of an attempt to disassemble or reverse engineer the
charger will void this warranty.
Webasto Charging Systems, Inc. refurbished TurboCords carry a one (1)-year
manufacturer’s warranty. If received as a service replacement, the warranty
will remain in effect for the remainder of the term of the originally purchased
equipment.
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Page 25
INDEX
A
auto-restart .................. 3, 10
B
BLUE STATUS Indic ator ...... 8,
9, 10, 12, 13
C
charge coupler ...... 4, 5, 9, 10,
12, 15, 17, 19
charge module ............... 5, 8
circuit breaker ............. 12, 15
components ....................... 5
customer support ................ i
D
dedicated circuit ................. 3
E
electric shock .......... 3, 18, 19
environmental rating......... 15
F
features ........................ 3, 18
G
GFCI ........................... 10, 19
M
manual stop......................... 10
O
output ground .................. 19
outlet ........ 3, 4, 6, 8, 10, 12,
13, 17
P
pilot signal wire ................ 19
R
RED TROUBLE indicator ..... 8,
10, 12, 13
release button .......... 5, 9, 10
S
SAE J1772 ............... 3, 15, 17
safety features .................. 18
serial number ....................... i
service ground .................. 18
STAT US indicator ........... 3, 8,
9, 10, 12, 13
T
temperature .......... 13, 15, 20
TROUBLE indicator ....... 8, 10,
12, 13, 18, 19
H
hanger ........................ 16, 17
W
wall receptacle ................ 6, 9
warranty ........................... 20
I
weight .............................. 15
insulated ........................... 19
indicator light ................. 8, 9
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21
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22600-03 Rev.04
Webasto Charging Systems
Customer Support
1-888-833-2148
evscs@webasto.com
Corporate Headquarters
Webasto Charging Systems, Inc.
EV Solutions™
800 Royal Oaks Drive, Suite 210
Monrovia, CA 91016-6347
Corporate phone: (626) 357-9983
or (888) 833-2148
evscs@webasto.com
www.evsolutions.com
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