AutomationElectric Vehicle (EV)Electrical WiringHow ToSmart Home
Trending

How to Wire AC Level 2 EV Smart Breaker Charger – 40A/32A

Electrical Technology
0 12 minutes read

Wiring a Fast AC Level 2 EV Smart Breaker Charger Using Direct Connect and Junction Box Kits for 32A Electric Vehicle Charging

Green Motion EV Smart Breaker Charger

As traditional vehicles are being replaced by electric vehicles (EVs), modern homes increasingly require a dedicated EV charging point. While rising fuel prices have encouraged EV adoption, high electricity rates can also increase charging costs. To address this challenge, one of the simplest and most cost-effective solutions is to install a Level 2 EV smart breaker charger.

With a Level 2 EV smart breaker charger, you can conveniently charge your vehicle at home wherever it is parked while avoiding unnecessary energy costs. The charger can be monitored, controlled, and scheduled remotely through a smartphone app. It can be control remotely from anywhere to optimize charging times based on utility rates. In addition, the Fast AC smart charger can be configured to pause charging during peak-rate periods and automatically resume charging during off-peak hours when electricity is less expensive. This helps reduce overall charging costs while ensuring your vehicle is ready when needed.

Hardwiring an EVSE (Electric Vehicle Supply Equipment) is generally more reliable than using a plug-in connection. A hardwired installation provides a permanent electrical connection, reduces potential points of failure, and helps ensure long-term performance and safety.

The Green Motion EV Smart Breaker Charger by Eaton is a 7.7 kW, 32A Level-2 EV charging kit which can be wired directly or with junction box . The kit with 25 ft cable can be installed directly into compatible Eaton BR loadcenters or PRL3X panelboards. The charger combines thermal-magnetic circuit breaker protection, GFCI protection, automatic fault reset, and SAE J1772 EV charging functionality into a single device.

In the following wiring and installation guide, we will use the Eaton Green Motion EV Smart Breaker Charger with required wiring connections, installation procedures, and safety considerations as per codes.

Wiring Smart Breaker Charger for EVs

Good to Know: The EV Smart Breaker Charger is designed for use with plug-in hybrid electric vehicles (PHEVs) and is compatible with all electric vehicles (e.g. Tesla, Lucid, Rivian) that support the universal J1772™ charging connector, in accordance with the SAE J1772 charging standard established by the SAE International.

Electrical Ratings & Specifications

  • Name: Green Motion EV Smart Breaker Charger by Eaton (BREVEM2040 & BABEVEM2040)
  • Voltage: 208-240V AC – 60 Hz – Single-Phase
  • Breaker Rating: 40A
  • Charging Current: 32A
  • Output Power: 7.7 kW at 240V, 6.6kW at 208V
  • GFCI: 20mA Ground Fault Protection
  • Connector Type: SAE J1772
  • Wireless Connectivity: Smart Control through IEEE 802.11 b/g/n and 2.4 GHz Wi-Fi
  • Listed: UL, CSA, NFPA Article 625, SAE J1772 2010 Ed., FCC Compliant, Part 15 and ANSI C12.20
  • Wiring Method: Hardwired – Direct Connect and Direct Connect kit with Junction Box
  • Compatible Enclosure: BR Loadcenter and PRL3X Panelboard

Click image or open in a new tab to enlarge

AC Level 2 EV Smart Breaker Charger - 2P 40A for 32A Charging

Before Installation …

Warning

  • Make sure to de-energize all power sources before beginning installation.
  • Installation must be performed only by a qualified electrician.
  • Install in accordance with NEC Article 625 and all applicable local codes.
  • The smart EV charger beaker should be used only for plug-in electric vehicles (PEV).

Code Requirements:

NEC 210.19(A)(1) specifies that conductors supplying continuous loads shall have an ampacity not less than 125% of the maximum load. In practical terms, this means that circuit breakers should not be loaded to more than 80% of their rated capacity when supplying a continuous load (defined as a load expected to run for 3 hours or more).

This is why the charger breaker rating is 40A while it is used for 32A of continuous charging load.

40A × 80% = 32A

The smart charger breaker is a dedicated circuit used for EV charging and it should not be used/shared with other load types as per NEC – 625.41

According to NEC Article 625, the coupling means (charging connector) of Electric Vehicle Supply Equipment (EVSE) must be stored or mounted within a specified height range to ensure accessibility and protection from physical damage.

  • Indoor installations: The charging connector shall be stored or located at a height of not less than 18 inches (450 mm) and not more than 4 ft (1.2 m) above the floor.
  • Outdoor installations: The charging connector shall be stored or located at a height of not less than 24 inches (600 mm) above the finished grade level.

GFCI & Grounding

NEC Section 625.54 requires ground-fault protection for electric vehicle supply equipment (EVSE). Since the EV Smart Breaker Charger incorporates a built-in Ground-Fault Circuit Interrupter (GFCI), a proper equipment grounding connection is required for safe and reliable operation. For this reason, the EV Smart Breaker Charger must be connected to a permanently grounded wiring system. 

EV Connector Conductor Identification

The EV charging cable contains five conductors with different wiring color codes and functions:

Note: The orange pilot conductor is intentionally 1 inch shorter than all other conductors and this length difference must be maintained to comply with NFPA 70 Article 625.19.

Good to Know: These wiring tutorials applies to Eaton Green Motion EV Smart Breaker Chargers (BREVEM2040 & BABEVEM2040) and associated models GMEV32BR-DC, GMEV32BAB-DC, GMEV32BR-JB, and GMEV32BAB-JB (For both plug-on and bolt-on installation).

Method 1: EV Direct Connect Installation

This method is used when the EV charger cordset can reach the parked vehicle directly from the loadcenter or panelboard. As the vehicle can be charged close to the panel, the conductor size is 10AWG for L1, L2, Ground and 18AWG for J1772 pilot and +12VDC for 32A charging with 40A breaker.

Click image or open in a new tab to enlarge

Wiring EV Direct Connect Smart Breaker Charger

The Direct Connect Kit includes the following components which can be easily wired in compatible Eaton BR loadcenter or PRL3X panelboard.

  • EV Smart Breaker Charger
  • J1772 EV Connector with 25-foot cordset
  • Cord Management Bracket
  • ¾-inch NM/SE Connector

Step 1 – Disconnect Power

  1. Turn OFF the main power supplying the loadcenter.
  2. Verify absence of voltage using appropriate test equipment.
  3. Remove the loadcenter deadfront cover.
  4. Ensure the EV Smart Breaker Charger handle is in the OFF position.

Step 2 – Install the EV Smart Breaker Charger

  1. Make sure there are adjacent 4 empty slots inside the panel as the breaker occupies 4 spaces.
  2. Connect the white neutral pigtail from the charger to the neutral busbar.
  3. Connect the green grounding pigtail to the grounding busbar.
  4. Install the breaker charger into the designated location:
    • BR Type: Plug onto the line bus.
    • BAB Type: Bolt onto the line bus.
  5. Tighten all connections according to manufacturer torque specifications.

Click image or open in a new tab to enlarge

How to Wire a Smart Breaker Charger for EVs

Step 3 – Route the EV Connector Cord

  1. Remove an appropriate knockout in the loadcenter.
  2. Install the supplied ¾-inch NM/SE connector.
  3. Route the EV connector cord through the connector.
  4. Secure the cord with the NM/SE locknut.

Step 4 – Connect the EV Connector Conductors

Terminate the EV connector conductors directly to the EV Smart Breaker Charger terminals:

Charger Terminal Wire Color Function
Terminal 1 Red Line 1
Terminal 2 Black Line 2
Terminal 3 Blue +12 VDC
Terminal 4 Orange J1772 Pilot
Terminal 5 Green Ground

Ensure all conductors are securely terminated.

Step 5 – Reassemble and Energize

  1. Reinstall the loadcenter deadfront.
  2. Restore power to the loadcenter.
  3. Verify that charger electronics power up.
  4. Confirm EV connector LEDs illuminate.
  5. Move the EV Smart Breaker Charger handle to the ON position.

Method 2: EV Smart Breaker Charger with Junction Box Kit

This method is used when the vehicle parking location is farther away from the loadcenter. A junction box allows the charging cable to be installed up to 250 feet from the panel.

Click image or open in a new tab to enlarge

 

The following conductor sizes (AWG) should be used when wiring the EV Smart Breaker Charger through a junction box. The required wire size depends on the installation method and whether the conductors are installed above ground or underground.

Conductor Wire Size in AWG
Up to 150 ft  Up to 250 ft
Line 1 (Red) #8 AWG Cu #6 AWG Cu
Line 2 (Black) #8 AWG Cu #6 AWG Cu
+12 VDC (Blue) #18 AWG #18 AWG
J1772 Pilot (Orange) #18 AWG RG6 Quad Shield AWG18
Ground (Green) #10 AWG Cu #10 AWG Cu

All conductors must be rated 90°C at 600V copper. In case of Eaton junction box, remove the L1/L2 terminal blocks to accommodate even bigger size i.e. 6 AWG. If using coaxial cable, the shield should be grounded at the panel.

Step 1 – Install the EV Smart Breaker Charger

Perform the same breaker installation procedure described in Method 1:

  • Connect neutral pigtail to the neutral bus.
  • Connect grounding pigtail to the ground bus.
  • Install breaker into loadcenter.
  • Verify breaker handle is OFF.

Click image or open in a new tab to enlarge

How to Wire EV Smart Breaker Charger with Junction Box Kit

Step 2 – Install Conduit Between Panel and Junction Box

  1. Mount the junction box at the desired charging location.
  2. Install conduit between the loadcenter and junction box.
  3. Pull all required conductors through the conduit.
  4. Follow conductor sizing requirements based on distance.

Note: For underground installations, the J1772 pilot conductor should be RG6 Quad Shield cable and the shield must be grounded at the distribution panel.

Step 3 – Mount and Prepare the Junction Box

  1. Open the junction box cover.
  2. Secure the enclosure to the wall.
  3. Remove required ¾-inch knockouts.
  4. Install NM/SE connectors.
  5. Route:
    • Field-installed conductors from the panel.
    • EV connector cord into the junction box.

Step 4 – Terminate EV Connector Conductors

Connect the EV connector conductors to the color-coded terminal blocks in the junction box:

Terminal Block Wire Color Function
Red Red Line 1
Black Black Line 2
Blue Blue +12 VDC
Orange Orange J1772 Pilot
Green Green Ground

Strip conductors approximately 10 mm (0.39 inch). Tighten terminal screws to 13.3-15.9 in-lb (1.5-1.8 Nm).

Step 5 – Connect Junction Box Conductors to Charger

At the loadcenter:

  1. Install two NM/SE connectors.
  2. Route conductors into the loadcenter.
  3. Terminate conductors to the EV Smart Breaker Charger terminals:
    • Terminal 1 to Line 1
    • Terminal 2 to Line 2
    • Terminal 3 to +12 VDC
    • Terminal 4 to J1772 Pilot
    • Terminal 5 to Ground
  4. Tighten all terminations securely.

Good to Know: There are two types of conductors in the cord i.e. High-voltage conductors e.g. Line 1, Line 2, Equipment ground and low-voltage conductors e.g. +12VDC and J1772 Pilot.

These conductors may share the same conduit only when all insulated conductors are rated for at least 250V. Otherwise, separate conduits must be used.

Step 6 – Install Cord Management Bracket

  1. Drill 1/8-inch (width) and 5/8 inches (depth) hole at both of the hole locations.
  2. Mount the bracket near the charging location.
  3. Secure using four #10 × 1½-inch screws.
  4. Install on a stud-backed wall whenever possible.
  5. Position so the charging cord can be wrapped neatly around the bracket.

Step 7 – Energize and Test

  1. Reinstall all covers and restore power.
  2. Verify BlinkUp and charger LEDs illuminate.
  3. Place breaker handle in ON position.
  4. Connect a vehicle and confirm charging operation.

Configuration and Wi-Fi Network Setting

When the EV Smart Breaker Charger has been successfully installed, restore power at the main service panel. The next step is to configure the charger using the mobile app.

To remotely control and monitor the EV Smart Breaker Charger over a Wi-Fi network, download the Eaton Brightlayer Home app from the Apple App Store (iOS) or Google Play Store (Android). The app provides convenient home energy management and EV charging control.

Using the app, you can remotely start, stop, monitor, and manage charging sessions from anywhere. It also provides real-time charging statistics, energy consumption data, and charging insights. In addition, you can schedule charging sessions based on Time-of-Use (TOU) utility rates to help reduce overall charging costs.

The app can send notifications for power outages, ground-fault events, charging status updates, and other charger-related alerts. You can also set a charging limit and adjust the charging current, with a minimum charging rate of 6A.

To commission and configure the EV Smart Breaker Charger for your preferred charge-management solution, download the EM Install app.

For Wi-Fi setup, app pairing, and advanced smart-control features, follow the step-by-step instructions in the guides below:

Warning

  • Make sure to disconnect the power supply by switching OFF the breaker in the main panel before doing any electrical work.
  • If you are unsure, contact a licensed electrician to do it according to the local area codes.

Disclaimer:

The author will not be liable for any losses, injuries, or damages from the display or use of this information or if you try any circuit in wrong format. So please! Be careful because it’s all about electricity and electricity is too dangerous. If you are unsure, contact a licensed electrician to do it according to the local area codes.

Resources:

EV Charger Wiring Series

  • How to Wire an EV Wall Charger – Hardwired and Plug-in
  • How to Wire ChargePoint Home Flex Charger for Every EV
  • How to Wire Smart Electric Vehicle Charging Station – 32A/80A
  • How to Wire 48A Level 2 Dual Port EV Charging Station
  • How to Wire and Use Tesla Gen 3 Mobile Connector Charger
  • How to Wire a Tesla Wall Connector & Universal EV Charger

Smart Devices Wiring Series

Wiring Standard GFCI & Breakers

Main Panels Wiring Tutorials

Wiring General Outlets & GFCI/AFCI Receptacles

Sizing Breakers, Wires & Panels

Tags
Electrical Technology
0 12 minutes read

Electrical Technology

We are a professional team specializing in Electrical and Electronic Engineering & Technology. Join us on the Electrical Technology Official WhatsApp Channel to receive the latest content, articles, and updates. You can also follow us on our social media platforms given below or subscribe via email to get premium engineering articles delivered directly to your inbox.

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button