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FREEWIRE Boost Charger, Installation Manual

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FREEWIRE Boost Charger Installation Manual Download Page 11

11

1

  OVERVIEW

Low Voltage 

Battery

Battery Management 

System

Cellular Modem

Computer Processor

Circuit Breakers

1

2

3

4 5 6

9

8

Breaker

Function

1

Main AC contactor

2

AC/DC battery charger 1

3

AC/DC battery charger 2

4

Battery air conditioning

5

Liquid cooling system pump

6

24 V system power supply

8

Computer processor power

9

Battery heaters

Located on the upper 

low-voltage shelf

Summary of Contents for Boost Charger

Page 1: ...Boost Charger DC Fast Charging Station Installation Guide Version 1 0...

Page 2: ...ation Warranty information and disclaimer The Limited Warranty you received with your Boost Charger is subject to certain exceptions and exclusions For example your use of or modification to the FreeW...

Page 3: ...igital 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 Th...

Page 4: ...akers 11 Unlocking and Locking the Front Access Door 12 Installation Overview 13 Concrete Pad Installation 13 Preparation 14 Boost Charger Shipping Crates 14 Boost Charger Overall Dimensions 15 Equipm...

Page 5: ...Powering on the Boost Charger 29 Commissioning the Boost Charger 30 Complete a Test Charging Session 30 3 BOOST CHARGER SPECIFICATIONS 32...

Page 6: ...Boost Charger must be grounded Use a grounded metal permanent wiring system that runs with circuit conductors and connects to the charger equipment ground on the Boost Charger An earth ground that com...

Page 7: ...f the installer WARNING To reduce the risk of injury be sure to follow lockout tagout practices and procedures to safeguard workers from unexpected energization Safety Shutdown The FreeWire Boost Char...

Page 8: ...iliar with the Boost Charger and the necessary tools and equipment to install it NOTE The FreeWire Boost Charger must be installed by a licensed contractor and a licensed electrician Boost Charger Com...

Page 9: ...arger Main Component Overview Circuit Breakers Internet Connection optional Remote e Stop Connection Grid AC Connections Ground Connection Heat Exchanger DC DC Converters Circulating Pump Battery Cool...

Page 10: ...ERVIEW Contactor Box Upper Low Voltage Shelf Lower Low Voltage Shelf AC DC Battery Charger Energy Meters CCS CHAdeMO EV Charger Controllers Low Voltage Fuse Board Programmable Logic Controller Power S...

Page 11: ...or Circuit Breakers 1 2 3 4 5 6 9 8 Breaker Function 1 Main AC contactor 2 AC DC battery charger 1 3 AC DC battery charger 2 4 Battery air conditioning 5 Liquid cooling system pump 6 24 V system power...

Page 12: ...es must be accessible Step 1 Remove the CHAdeMO charge cable from its respective holder Step 2 Insert the key and turn to unlock Step 3 Remove the key Step 4 Insert the door tool and pull open the has...

Page 13: ...on and activate the FreeWire Boost Charger as described in section 2 Note Always check local codes and requirements to ensure that the installation is compliant Concrete Pad Installation The FreeWire...

Page 14: ...oling shipping crates lifting equipment and work trucks 6 Confirm that all parts tools and equipment are available 7 Become familiar with the entire Boost Charger installation process Important In geo...

Page 15: ...15 Boost Charger Crate Packing List Boost Charger Door access keys 2x Door Tool Boost Charger Overall Dimensions 1 OVERVIEW...

Page 16: ...as required 15 16 wrench and socket 2 Phillips screwdriver T27 tamper proof pin in Torx driver and bit 15 16 Crows foot wrench Torque wrench 200 ft lbs Torque wrench 100 in lbs 2 AWG lug grounding the...

Page 17: ...Charger and prevent it from swaying or tilting Pay specific attention to the Boost Charger s center of gravity to avoid the unit from falling Add additional nylon straps and sling pick up points arou...

Page 18: ...tynes don t protrude too far that they hit the wall when moving the Boost Charger onto the pad Uncrating the Boost Charger is a two person job Make sure there is ample space to safely work around the...

Page 19: ...19 Step 3 Remove the bolts from the side panel Step 4 Release the six side and two top hasps which are used to hold the side panel of the shipping crate 2 INSTALLATION OF THE BOOST CHARGER...

Page 20: ...two people carefully remove the side panel from the shipping crate as shown Step 6 Using two people carefully slide the remaining four panel structure away from the Boost Charger 2 INSTALLATION OF TH...

Page 21: ...21 Step 7 Carefully cut metal bands from the Boost Charger using a band cutter Step 8 Carefully remove the protective plastic from the Boost Charger 2 INSTALLATION OF THE BOOST CHARGER...

Page 22: ...old in the front and backside kick panels using a pin in torx bit Set the hardware aside for future use Step 10 Remove both the front and backside kick panels and set them aside for re installation la...

Page 23: ...Charger to the shipping base using a 15 16 inch socket wrench Step 12 Using a forklift or crane carefully lift the Boost Charger from the base of the crate and station it at the concrete foundation p...

Page 24: ...he corresponding holes in the bottom mounting beams then lower the Boost Charger over the bolts Caution Carefully guide the conduit into the front access door Caution To ensure that the service wiring...

Page 25: ...e room to maneuver around the Boost Charger Step 5 Tighten the outer 4 nuts first Then tighten the center front and back nuts by hand turning the lower nuts until they are flush against the Boost Char...

Page 26: ...ode enforcement officer for guidance The FreeWire Boost Charger can be wired up to an optional external safety shutoff switch Installation of an external switch does not disable the switch mounted on...

Page 27: ...utoff switch In order to wire up the external safety shutoff switch the red jumper shown below must first be removed Step 2 Wire up the remote shut off using 20 AWG wire as shown below Step 3 Be sure...

Page 28: ...the photo below Step 4 Verify the length of the wire needed to connect to the Boost Charger terminal block as shown in the photo below Trim any excess wire Note Make sure the wire can reach the termi...

Page 29: ...duct if There is Any Damage to the Charging Cable or Charging Connectors Powering on the Boost Charger There is an emergency stop button however there is no separate on off switch for the Boost Charge...

Page 30: ...ioning process Step 1 Download the free EV Connect App on your smart phone Step 2 Register or login to your mobile app as a guest Step 3 Tap the Charge button and scan the QR code or type the ID locat...

Page 31: ...tes correctly and no errors exist the installation is complete If the Boost Charger does not power up or fails to begin a charging session confirm that the wiring is properly connected If the Boost Ch...

Page 32: ...C 500 VDC Supported Connector Types CCS1 SAE J1772 Combo CHAdeMO Charge Cable Length 140 in User Interaction Display Full color 24 inch LCD display for driver interaction Authentication RFID ISO 15693...

Page 33: ...ury or death during charging Do not disconnect charger connector while the EV is charging Environmental Requirements Location Outdoor Operating Temperature 20 C to 55 C 4 F to 131 F Storage Temperatur...

Page 34: ...ional questions please contact 415 484 9590 support freewiretech com 1933 Davis St Suite 301A San Leandro CA 94577 Boost Charger Installation Guide v1 0 8 24 2020 Part Number 770 00003 01 www freewire...

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