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This document is a

Property of BTCPower Inc.

and shall not be

copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.

10-Dec-20

Revision

150kW High Power DC Charger

INSTALLATION AND USER’S

MANUAL

Page

APPENDIX

12.

Appendix

12.1.

Component Information

CCS1 High-Power Liquid Cooled Coupler (500A Rated)

Part

Details

Part Number:

190-0289-01

Manufacturer:

Huber + Suhner

Standard Position of Connector

Cable Length or Dimension A :

3400 mm or 11.15 ft

Optional Longer Cable Length Available with Dimension A of

7620 mm or 25 ft

Содержание EVDSP-200-4-120-0-2-C-4-0

Страница 1: ...150kW High Power DC Charger INSTALLATION AND USER S MANUAL BTCPOWER INC 1719 S GRAND AVE SANTA ANA CA 92705 WWW BTCPOWER COM...

Страница 2: ...ithout further notice No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without written permission of BTCPower Inc Changes or modif...

Страница 3: ...penser 12 5 Pre Installation 13 5 1 Location Selection 13 5 2 Cable Reach 14 5 3 ADA Consideration 15 5 4 List of Parts Materials and Tools Needed for Installation 17 6 Transportation and Handling 18...

Страница 4: ...TABLE OF CONTENTS Table of Contents 9 3 Operating Instruction 40 9 4 Troubleshooting 43 10 Maintenance 48 11 Product Disposal 53 12 Appendix 54 12 1 Component Information 54 a CCS1 High Power Liquid...

Страница 5: ...andards Failure to observe this precaution could result in severe injury or death Read this manual completely and become familiar with the equipment prior to performing any procedures specified in the...

Страница 6: ...manual and on labels affixed to the equipment unit DANGER Indicates High Voltage It calls attention to items or operations that could be dangerous to person s operating this equipment Read and follow...

Страница 7: ...ase voltage into DC voltage to directly charge an electric vehicle s lithium ion battery It is capable to charge all electric vehicles compliant with CHAdeMO charging system and Combined Charging Syst...

Страница 8: ...3 EQUIPMENT DESCRIPTION 3 Equipment Description 150 kW HIGH POWER BOX TOWER COMPONENT DESCRIPTION 1 50KW 3 Power Module 2 50KW 2 Power Module 3 50KW 1 Power Module 4 Output Contactors Power Module 3 5...

Страница 9: ...S MANUAL Page 9 of 63 EQUIPMENT DESCRIPTION 350A 200A CHARGE DISPENSER COMPONENT DESCRIPTION 1 15 inch Outdoor Rated Display and Touch Screen 2 Encrypted Insert Card Reader 3 RFID Card Reader 4 High...

Страница 10: ...EM COMPONENTS Power Box Tower ITEM DESCRIPTION MODEL NUMBER SKU 1 DCFC Power Box Dual Output SCCR 65kA EVPC 150 2 480 3 65 HPCT 150 480 2 Dispenser ITEM DESCRIPTION MODEL NUMBER SKU 2 DCFC 350A Dispen...

Страница 11: ...SCCR 65 kA DC Output Output Voltage Range 50 950 VDC Maximum Output Current CCS 350 A CHAdeMO 200 A Maximum Output Power 150 kW Minimum Output Current 5 A Output Ripple Current 15 Ap p Bandwidth 1 kHz...

Страница 12: ...iliary Input Current 21 A 10 A Input Frequency Range 47 63 Hz Panel Breaker 30 A Power Quality IEEE 519 and IEC 6200 3 4 DC Input Input Voltage Range 50 920 VDC Input Current Range 5 500 A DC Output D...

Страница 13: ...mining Suitability of Site for Cellular Connectivity o Ensure that installation location meets the Cellular Signal Strength Criteria below Parameter Min Value Device Notes RSSI 69 dBm SureCall If RSSI...

Страница 14: ...nser come in different lengths depending on the dispenser configuration and cable connector type The table below shows the connector type with its corresponding cable reach while the figure shows the...

Страница 15: ...es public accommodations and commercial facilities to be readily accessible to and usable by individuals with disabilities Adoption of the 2010 Standards also establishes a revised reference point for...

Страница 16: ...ALLATION For information about the ADA including the revised 2010 ADA regulations please visit the Department s website www ADA gov or for answers to specific questions call the toll free ADA Informat...

Страница 17: ...ase Item Part Description Quantity Remarks 1 OM3 multimode 50 125 m ST connectors on both ends 2 pairs per dispenser Recommended supplier https fibercablesdirect com 2 18AWG Twisted Pair Shielded Inte...

Страница 18: ...ls of its packaging and dimensions for both tower and dispenser Item Width in Depth in Height in Weight lb Power Box Tower 49 42 90 up to 2 100 Dispenser 37 30 103 up to 740 6 2 Transport Handling and...

Страница 19: ...m visual inspection on the shipment and immediately notify BTCPower Project Manager for any damage Unload and carefully inspect the crate or packaging for any damage caused by mechanical impacts or an...

Страница 20: ...observe this precaution could result to severe injury or death WARNING The equipment may be installed outdoors but only use under environment conditions as stated in this document Do not perform any l...

Страница 21: ...res to prevent falling when moving or hoisting the unit Using Forklift or Pallet Jack Care should always be taken when lifting the charger using a forklift or pallet jack Forks should be extended comp...

Страница 22: ...L Page 22 of 63 INSTALLATION BTCPower s recommendation in reference to the M12 lifting eye bolt specification and the charger s maximum weight is to use all four 4 eye bolts and keep the vertical angl...

Страница 23: ...f apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 23 of 63 INSTALLATION NOTE After the Power Box Tower is fixed on its locatio...

Страница 24: ...sion 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 24 of 63 INSTALLATION 7 2 Mounting Procedures 7 2 1 Clearance Around the Unit Clearance surrounding the unit m...

Страница 25: ...D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 25 of 63 INSTALLATION Dispenser Installation Drawing 7 2 2 Tower and Dispenser Mounting Both the Tower and Dispenser must be fixed on...

Страница 26: ...AND USER S MANUAL Page 26 of 63 INSTALLATION Power Box Tower Footer Drawing The illustration below shows the drilling layout for the Power Box Tower Only four 4 points are needed to fix the unit on t...

Страница 27: ...TION AND USER S MANUAL Page 27 of 63 INSTALLATION Dispenser Footer Drawing The illustration below shows the drilling layout for the Dispenser Only four 4 points are needed to fix the unit on the concr...

Страница 28: ...or manufacture of apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 28 of 63 INSTALLATION 7 3 Electrical and Communication Serv...

Страница 29: ...used as the basis for sale or manufacture of apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 29 of 63 INSTALLATION 1 Tower 1...

Страница 30: ...nser Requirements AC Input 120 VAC Single Phase 20 Amps FLA Auxiliary power to power the heat exchanger payment system and display module DC Input from Tower 1 000 V Communication conduit between the...

Страница 31: ...0 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 31 of 63 INSTALLATION TOWER AC Input Input Terminal Lug Terminal Lug P N Opening per Pole Wire Range Torque Requirement 600...

Страница 32: ...MANUAL Page 32 of 63 INSTALLATION DC Converter Output Terminal Lug from Converter to Dispenser Single or Dual High Output Configuration Terminal Lug P N Opening per Pole Wire Range Torque Requirement...

Страница 33: ...written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 33 of 63 INSTALLATION 350 kW Dispenser DC Input Terminal Lug Terminal Lug P N Opening per Pole W...

Страница 34: ...s the basis for sale or manufacture of apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 34 of 63 INSTALLATION Dispenser Termina...

Страница 35: ...he basis for sale or manufacture of apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 35 of 63 INSTALLATION Tower Power Box Inte...

Страница 36: ...and inspection on both tower and dispenser s using the HPDC Charger Commissioning Checklist which was provided together with this manual All instructions listed in the commissioning checklist are con...

Страница 37: ...ec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 37 of 63 OPERATION 9 Operation 9 1 System Power Up DANGER The charger must NOT be started or put into use without havin...

Страница 38: ...ion 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 38 of 63 OPERATION 9 2 Output Connectors DANGER Danger of death serious personal injury and burns Improper hand...

Страница 39: ...atus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 39 of 63 OPERATION 9 2 2 CCS1 Connector 500 A Cable Length 11 15 ft 13 15 ft for mo...

Страница 40: ...ting Instruction CAUTION If at any time you feel the equipment to be unsafe shut off the electricity at the Circuit Breaker and immediately contact Customer Support DO NOT use your charger until the p...

Страница 41: ...paratus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 41 of 63 OPERATION Starting a Charging Session continued SCREEN DESCRIPTION SCRE...

Страница 42: ...on 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 42 of 63 OPERATION Starting a Charging Session continued SCREEN DESCRIPTION SCREEN 7 Charging in Progress and Di...

Страница 43: ...te with PowerModule in power cabinet tower Check communication cable between multinode and power module TOWER_SAFETY_ERROR Charger Power Cabinet 2 High if in faulted state Medium if reason for shutdow...

Страница 44: ...cle not connected properly or for some vehicle if we didn t hold and lift connector 5 Due to cord length or weight Cable plugged in but getting pulled and not making proper contact If issue observed w...

Страница 45: ...VEHICLE_EV_CONTACTOR_CLOSE Vehicle 5 Low This is timeout after Cable Check is completed For Chademo vehicle should close contactor in 4sec after D2 signal raised by charger Vehicle issue TIMEOUT_CHARG...

Страница 46: ...hanged from StateC to StateB Pilot signal failure If frequent then report probably tech visit on site VEHICLE_COMMUNICATION_TIMEOUT Vehicle 5 Low CCS request response timeout If frequent then report p...

Страница 47: ...ehicle 5 Low Charger compatibility error Vehicle issue CCS_VEHICLE_NO_DATA_ERROR Vehicle 5 Low No charge parameters from vehicle Vehicle issue CCS_VEHICLE_CHARGER_INTERNAL_ERROR Vehicle 5 Low Vehicle...

Страница 48: ...components Maintenance Items Perform periodic maintenance of both Power Box Tower and Dispenser units Outlined below are the mandatory maintenance works for the Power Box Tower unit that must be carri...

Страница 49: ...the prescribed interval SCOPE MAINTENANCE WORK INTERVAL External Maintenance Check the Dispenser for mechanical damage corrosion restriction of IP degree of protection abnormal odor etc Check branding...

Страница 50: ...nnual Performance Testing Measure Incoming AC Voltage Perform Interlock Testing Check if HMI Nayax touch screen and pushbutton are operating properly Perform testing on charging cable using Comemso An...

Страница 51: ...epeater Extender Bus Line 11 170 0243 01 Switching Power Supply 12V 12 170 0038 01 General Purpose Relay 13 140 0160 01 Control Transformer 14 201 0175 01 50kW Power Module Assembly 15 190 0128 01 HPC...

Страница 52: ...otation CCS 1 27 Liquid Cool Cable 4m Right Rotation CCS 1 28 Liquid Cool Cable 25 Length CCS 1 29 190 0113 01 120VAC Cooling System 30 190 0114 01 Cool Cable Coolant CP3 002 5l 6L 31 190 0063 01 CHAd...

Страница 53: ...environmental impacts of our products in every stage of the product life cycle from design to manufacturing to usage and its disposal Proper disposal of our product and parts should be observed to re...

Страница 54: ...0kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 54 of 63 APPENDIX 12 Appendix 12 1 Component Information a CCS1 High Power Liquid Cooled Coupler 500A Rated Part Details Part Number 190 0...

Страница 55: ...permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 55 of 63 APPENDIX Connector Rotated Right 60 15 Cable Length or Dimension A 4009 mm or 13 15 ft Connecto...

Страница 56: ...S MANUAL Page 56 of 63 APPENDIX c Cool Cable Coolant Part Details Part Number 190 0114 01 Manufacturer Huber Suhner Description Non conducting fully synthetic oil Readily biodegradable High dielectri...

Страница 57: ...CPower Inc and shall not be copied reproduced or used as the basis for sale or manufacture of apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USE...

Страница 58: ...apparatus without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 58 of 63 APPENDIX d SAE J1772 CCS1 Coupler 200A Rated Part Details Part Numbe...

Страница 59: ...D USER S MANUAL Page 59 of 63 APPENDIX 12 2 Cooling Unit System Overview a Main Parts b Refiling Coolant in Cooling Unit Tank Cooling Unit Tank is filled full of coolant prior shipment In case of low...

Страница 60: ...us without written permission 10 Dec 20 Revision D 150kW High Power DC Charger INSTALLATION AND USER S MANUAL Page 60 of 63 APPENDIX To ensure better fill in process the coolant temperature must be ov...

Страница 61: ...Charger INSTALLATION AND USER S MANUAL Page 61 of 63 APPENDIX Start pump for around 60 seconds o Place an object to continuously engage the relay contactor and start the pump o Coolant flows into the...

Страница 62: ...chez C 23 Apr 20 Added notes to specify that the bottom of both tower and dispenser must be sealed to the ground Changed the Cover Illustration Added Manufacturer information Added the model number an...

Страница 63: ...RY Revision Date Description Originator C 23 Apr 20 Added back the updated Error Codes and Recommended Parts List Deleted Warranty Section Added Product Disposal Section Added the following informatio...

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