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How to Wire Smart Electric Vehicle Charging Station – 32A/80A

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Wiring Level 2 EV Charging Stations Using Hardwired and Plug-In Connections – 32A to 80A

Leviton’s Electric Vehicle Charging Stations

The Leviton EV Series Electric Vehicle Charging Stations are Level 2 EV chargers designed for residential and commercial electric vehicle charging applications. Depending on the model, these chargers support charging currents ranging from 32A to 80A and require branch circuit breaker ratings from 40A to 100A at 240V for both hardwired and plug-in installations.

The chargers feature a built-in J1772 connector, making them compatible with most electric vehicles. Tesla vehicles can also be charged by using a compatible NACS (Tesla) adapter.

With high-speed Level 2 AC charging capability, the EV Series chargers can provide up to 76 miles of driving range per hour of charging when configured for 80A operation.

The charging station can be installed either as a permanent hardwired connection or as a plug-in unit using a NEMA 14-50 receptacle. In addition, select models support smart features through the Charging Station Management Software (AmpUp) platform and can be remotely monitored and controlled using the My Leviton smartphone app. Furthermore, the charger’s operation can be enabled and managed using RFID cards.

How to Wire Leviton's EV Charging Stations for 32A to 80A Charging (Hardwired & Plug-in)

The available models, with variant and features are as follows:

Model Version / Variant Features
EV320 Standard version Standard features
EV32W Smart version Works with App
EV40P Smart version Works with App
EV480 Standard version Standard features
EV48G Commercial version Without LCD screen
EV48S (U.S.) Commercial version With LCD screen and Management Software
EV48S-F (Canada) Commercial version With LCD screen and Management Software
EV48W Smart version Without LCD screen and works with App
EV48S-DP Dual Port version With LCD screen and Management Software
EV800 Standard version Standard features
EV80G Commercial version With Management Software
EV80S Commercial version With LCD screen and Management Software
EV80S-F (Canada) Commercial version With LCD screen and Management Software
EV80W Smart version Without LCD screen and works with App

Although the charger comes with a built-in J1772 connector, which is the standard universal connector for EV charging, a NACS adapter (sold separately) can be used to charge Tesla vehicles. Therefore, the charger can be used to charge all types of electric vehicles.

Electrical Ratings & Specifications

  • Name: Electric Vehicle Charging Station – Leviton’s EV Series
  • Voltage: 208-240V AC – 60 Hz – Single-Phase
  • Breaker Rating: 40A to 100A 
  • Charging Current: 32A, 40A, 48A, 80A – Adjustable from 16-40 in EV40P.
  • Output Power: Min 7.6kW at 32A – 240V. Max 19.2kW at 80A – 240V
  • Charging Speed (est Max.): up to ~76 miles of range per hour at 80A
  • GFCI / RCD: 20 mA CCID per UL 2231
  • Wire Size: (Hardwire) = #6 to #3 AWG copper
  • Connector Type: SAE J1772 (Universal) or SAE J3400 – NACS Adapter (Tesla-style)
  • Charging Cable: 18 – 25ft (5.5 m – 7.6 m) Cable
  • Input Cable: 3 ft ( 1 m) to NEMA 14-50P plug
  • Connectivity: 2.4 GHz Wi-Fi (802.11 a/b/g/n) Wi-Fi and Bluetooth – Pair with the My Leviton app & compatible with Samsung Smartthings, RFID authentication and Charging Station Management Software (AmpUp)
  • Listed: UL 2594, 2231-1, 2231-2, 2251, 62, 991, 1998, 840. NFPA 70 (NEC) Article 625 & CSA compliant with cUL listed.
  • Wiring Method: Hardwired, or Plug-in via NEMA 14-50 or NEMA 6-50 Plugs & Receptacles via  L1 (Hot 1), L2 (Hot 2) and Ground (EGC).
  • Mounting: Wall mount or pedestal mount
  • Enclosure: UL / NEMA Type 3R rated for Indoor / Outdoor Mounting

Circuit Rating, Max Load & Charging Range

The breaker/circuit rating determines the maximum amperage the charger can be used for (different models). Per NEC continuous-load rules (NEC -210.19(A)(1), the EV charger must be set so its load never exceeds 80% of the circuit breaker’s rating. In other words, the breaker must be rated at no less than 125% of the charger’s continuous load).

The following table shows the breaker size, charging current, output power and estimated charging range per hour at 240V AC supply for different models.

Model Breaker Size Charging Current Output Power Est. Range/Hour
EV32 40A 32A 7.6 kW 31 mi / 50 km
EV40 50A 40A 9.6 kW 39 mi / 62 km
EV48 60A 48A 11.5 kW 47 mi / 75 km
EV80 100A 80A 19.2 kW 76 mi / 122 km

Good to Know: Plug-in installation with a NEMA 14-50 or 6-50 receptacle is only permitted on a 40A or 50A breaker (32A or 40A charging, respectively). Every other amperage setting (e.g. 16A, 48A, 50A, & 100A charging) requires a hardwired installation. In Canada, plug-in installation is permitted only on a 50A circuit.

The Leviton’s EV Series charging stations can be wired and installed using two methods in indoor or outdoor locations:

  1. Hardwired Installation (Direct Connection)
  2. Plug-in Installation using a NEMA 14-50 Receptacle

Method 1 – Hardwire Installation

Hardwiring provides the most secure installation and allows higher charging currents. Hardwired installation is recommended for permanent installations and to avoid nuisance tripping of GFCI/RCD (mostly occurs in plug-in installations).

  1. Turn off power at the main and circuit breaker/fuse feeding the charger circuit. Verify with a voltmeter that the circuit is de-energized before touching any conductors.
  2. Install a a properly sized branch circuit breaker based on the model and charging current (Table is given above). For instance, use #3 AWG copper for 80A charging supplied by a 100A breaker.
  3. Select a mounting height location (up to 2-4 ft (24″ to 48″) above finished floor) where the charging cable can easily reach the vehicle’s port with slack.
  4. Using the wall-mounted bracket as a template (or the supplied mounting drill points), mark four screw-hole locations on the wall. Drill four holes of 0.35 in. (8.5 mm) in diameter / 2.05 in. (52 mm) in depth and insert wall anchors. Align the bracket’s screw holes with the wall holes. Insert the four M6 hexagonal expansion screws and tighten to secure the bracket. Use a level to confirm it is plumb.
  5. Route the incoming branch-circuit conductors (L1 (as Hot 1), L2 (as Hot 2), and ground (EGC) into the charger’s rear wiring compartment through the designated knockout. No neutral conductor is required in this configuration.
  6. Strip conductors to the appropriate length and land them on the charger’s terminal block: i.e. Black on L1, Red on L2, and Green or bare conductor on PE (ground terminal). Torque connections to the value specified inside the enclosure cover.
  7. Align the rear notch of the charger with the wall-mounted bracket and hang the unit on the bracket. Now, secure the charger to the bracket using the two M5 anti-theft/teeth screws provided.
  8. Restore power by turning ON the associated branch circuit breaker. Power on the unit and confirm the LED indicator shows a steady BLUE (Standby/Ready) light. (See the LED status indication table given in the below section 6 & 7).

Click image or open in a new tab to enlarge

Hardwired Installation of EV Charging Station for 80A Charging

Cautions: For 208V supply in a 120/208V 3ΦY panel,

The EV Series charger supports 208V Wye systems. In the three-phase panel, connect either L1-L2, L2-L3 or L1-L3 with ground (do not connect Neutral). In other words, only two phases (lines) are used and the third (phase or line) remains unused.

NEC Considerations for Hardwired Installs

  • NEC 625.54 (Personnel GFCI Protection): GFCI protection is required for EV charging receptacles. Hardwired EV chargers generally do not require upstream GFCI protection unless specified by the manufacturer. Current Leviton’s EV series charger models include an internal CCID (Charge Circuit Interrupting Device) for personnel protection.
  • NEC 625.42 (Continuous Load): Branch-circuit conductors and overcurrent protection must be sized at 125% of the charger’s maximum output rating.
  • NEC 625.43 (Disconnecting Means): A readily accessible disconnect must be provided. The branch circuit breaker may serve as the disconnect if it is within sight of the charger. Equipment rated above 60A or 150V-to-ground requires a lockable disconnect.
  • NEC 210.8 (Location-Based GFCI Protection): Receptacles installed in garages, outdoors, or other specified locations may require GFCI protection regardless of EV charging requirements. Both Articles 625 and 210.8 must be considered.
  • NEC 625.56 (Wet Locations): Receptacles installed in wet locations must be protected by a weatherproof, in-use-rated enclosure.

Method 2 – Plug-In Installation (NEMA 14-50)

The NEMA 14-50R is a 3-pole, 4-wire, 125/250V, 50A receptacle used for electric ranges, RV pedestals and EV charging. It is installed upstream the charger where the 3ft input charger cable can reach easily. The two hot conductors connects to the two energized legs of a 240V (or 208V, 3-phase-derived) circuit protected by a 50A breaker. the EV series chargers itself do not use the neutral, but the 14-50 receptacle standard required the neutral connection with Ground.

To wire an industrial-grade NEMA 14-50 receptacle, connect the THHN/THWN-2, #6 AWG copper, four conductors (2 hots (L1, L2) + Neutral + Ground)  from a 2-pole, 50A standard/GFCI breaker for 40/50A charging as follow:

  • L1 i.e. Hot 1 (Black wire) to X (Brass screw)
  • L2 i.e. Hot 2 (Red wire) to Y (Brass screw)
  • Neutral (White wire) to W (Silver screw)
  • Ground (Green/Bare wire) to G (Green screw)

For the rest of hardwired installation, follow the following steps:

  1. Turn off power at the main breaker
  2. Install a 240V single-phase 2-pole, 50A dedicated branch circuit breaker using #6 conductors (for 50A receptacle).
  3. Install the heavy duty / EV rated NEMA 14-50R receptacle within reach of the EV charge station 3ft input cord (18-48 inches above floor) as per terminal wiring given above.
  4. Select a mounting location for the charger that allows the 18-25 ft. output (charging) cable to comfortably reach the vehicle’s charging port, and keeps the 3 ft. input cable within reach of the installed NEMA 14-50 receptacle.
  5. Confirm the wall structure can anchor the bracket (2″ x 4″ stud) or solid wall is required.
  6. Mount the charger at a height between 2 ft. (600 mm) and 4 ft. (1200 mm) from the ground using M6 (anti-theft) screws. Now, tighten the screws to lock the charger onto the bracket.

Click image or open in a new tab to enlarge

Plug-in Installation of EV Charging Station with NEMA 14-50 & J1772 Connector for 40A Charging

Warning: Don’t use the standard NEMA 14-50 receptacle rather than industrial grade receptacle.

Install Replacement Cord

If you need to install a replacement charging cord (for example, the EC80A replacement 18-ft cord for an 80A Level 2 EV charging station with a J1772 charge connector), follow the instructions below:

  1. Remove the front and rear covers by loosening the 13 screws.
  2. Remove the three terminal screws and disconnect the cord terminal lugs from the circuit board. Then unplug the CP (Control Pilot) cable.
  3. Plug the orange-colored CP cable from the new replacement cord into the circuit board.
  4. Connect the black wire (L1/Hot 1) to the “L1/O” terminal.
  5. Connect the red wire (L2/Hot 2) to the “L2/O” terminal.
  6. Connect the green wire (Ground) to the “G/PE” grounding terminal.
  7. Tighten the terminal screws to a torque of 8.5–10.5 in-lb.
  8. Reinstall the front and rear covers.

Pro Tip: The same wiring diagram can also be used for the replacement or installation of the input power conductors, when required.

To do so, connect the input wires as follows:

  • Black wire (L1/Hot 1) to the “L1/IN” terminal
  • Red wire (L2/Hot 2) to the “L2/IN” terminal
  • Green wire (Ground) to the “G/PE” grounding terminal

Click image or open in a new tab to enlarge

Install Replacement Cord for Leviton's EV Charger

 

Charger Activation & Smart Control via App

If the charger model supports Charging Station Management Software, you can set up and activate the charger with AmpUp using the following steps:

  1. Visit the AmpUp activation page or scan the QR code on the green AmpUp sticker located on the charger.
  2. Select the charger brand and click Continue. Review the checklist, then click Get Started.
  3. Enter your name, email address, and phone number.
  4. Select an existing site or create a new one. For a new site, enter the installation address, host contact information, and the electrical panel capacity limit.

If the charger model supports Wi-Fi connectivity, the charger can be monitored and controlled remotely using a smartphone. The app allows users to view the charging station status, receive fault notifications, and manage various smart home devices, including EV charging, lighting controls, and smart load centers.

To do so, add the EV charger to the My Leviton app, and follow the on-screen instructions.

  • Power ON your EV charger and place it into Setup Mode. When the charger is in Setup Mode, the blue LED indicator will flash.
  • If the blue LED is not flashing, power cycle the charger and try again.
  • Follow the instructions in the My Leviton app to add your charger and connect it to your Wi-Fi network.

To enable or disable RFID access control on your EV Series Smart Home Charger, open the My Leviton app and follow the path below:

Device → Settings → RFID Card

From this menu, you can enable or disable RFID authentication for your charger.

Good to Know:

  • RFID access control is disabled by default on all units. Once enabled with the Admin card, RFID access control cannot be disabled. Hence, only activate it if you intend to restrict charging to authorized cardholders.
  • The EV48S/EV80S models pair with AmpUp charging-station management software; the EV40P, EV32W, EV48W, and EV80W models pair with the My Leviton app over Wi-Fi (802.11 b/g/n).

Status LED Lights

The LED indicator indicates the status of EV series chargers by Leviton (all models) as shown in the following table.

Indicator Status Indication
Solid BLUE Standby / Ready Unit is powered and idle, waiting for a vehicle connection or user authorization.
Solid GREEN Waiting for Charge Vehicle connector is plugged into the vehicle inlet; charging has not yet started.
Flashing GREEN Charging Active charging session in progress.
Solid RED Fault An error has occurred – see Section 7, Error & Warning Messages.
Flashing BLUE My Leviton Setup Mode Wi-Fi provisioning mode (EV40P, EV32W, EV48W, EV80W).

Good to Know:

  1. Confirm user authorization if RFID access control is enabled (tap Standard RFID card to the reader).
  2. Connect the J1772 charging connector to the vehicle’s charging inlet and press & hold the button on top of the plug, insert, then release.
  3. Charging begins automatically and the indicator light flashes GREEN for the duration of the session.
  4. When charging is complete, press the button on the connector to release it from the vehicle and unplug.

Fault Codes & Troubleshooting

The following table shows the error and warning message through the RED led indictor on the charger (EV48G / EV48S / EV80G / EV80S and other EV series charger) which can be used for maintenance and troubleshooting

Status Red LED Indicator Remark
Emergency Fault Constantly bright Power cycle the unit
Input Over-Voltage (OVP) 1 flash + 3-sec pause Auto recover
Input Under-Voltage (UVP) 2 flashes + 3-sec pause Auto recover
Output Over-Current (OCP) 3 flashes + 3-sec pause Auto recover – unplug and reinsert connector
Over-Temperature (OTP) 4 flashes + 3-sec pause Auto recover
CCID / RCD Abnormal 5 flashes + 3-sec pause Auto recover – unplug and reinsert connector
Ground Fault 6 flashes + 3-sec pause Auto recover
Control Pilot Fault 7 flashes + 3-sec pause (or blinking) Auto recover – unplug and reinsert connector
Relay Fault 8 flashes + 3-sec pause Contact Electrician / Customer Service
CCID / RCD Self-Test Fault 9 flashes + 3-sec pause (or Stable red) Contact Electrician / Customer Service
Relay Self-Test Fault 10 flashes + 3-sec pause Contact Electrician / Customer Service
Meter Fault Keeps blinking Contact Electrician / Customer Service

Good to Know:

For faults marked “Auto Recover,” first unplug and firmly reinsert the vehicle connector before assuming a hardware failure.

Instruction and Precautions

  • Disconnect the power supply and verify that the circuit is de-energized before beginning the installation.
  • Ensure the installation complies with NEC Article 625 (Electric Vehicle Power Transfer System), as well as other applicable NEC requirements, including Articles 110, 210, 220, 240, and 310. Also comply with all applicable local electrical codes and the requirements of the Authority Having Jurisdiction (AHJ).
  • In accordance with NEC Article 625, mount the EV connector holster between 18 in. (450 mm) and 4 ft (1.2 m) above the floor for indoor installations, and at least 24 in. (600 mm) above grade for outdoor installations.
  • In areas prone to frequent lightning or thunderstorms, install a Surge Protective Device (SPD) at the service panel to help protect the EV charging station from transient voltage surges.
  • Install the EV charging station in accordance with the National Electrical Code (NEC), the Canadian Electrical Code (CEC), and all applicable local codes and amendments governing Electric Vehicle Supply Equipment (EVSE). Consult your local electrical inspector or AHJ before beginning the installation if required.
  • This equipment must be installed, adjusted, and serviced only by a qualified and licensed electrician who is familiar with EV charging equipment, applicable electrical codes, and the associated hazards.
  • Failure to follow these instructions may result in electric shock, fire, serious personal injury, death, or damage to the equipment and property.

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

Smart Devices Wiring Series

Wiring Standard GFCI & Breakers

Main Panels Wiring Tutorials

Wiring General Outlets & GFCI/AFCI Receptacles

Sizing Breakers, Wires & Panels

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0 14 minutes read

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