BTCPower EVPC-150-2-480-3-65 Installation And User Manual
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BTCPower EVPC-150-2-480-3-65 Installation And User Manual

150kw high power dc charger
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150kW High Power DC Charger
INSTALLATION AND USER'S MANUAL
BTCPOWER, INC.
1719 S. GRAND AVE. SANTA ANA, CA 92705
WWW.BTCPOWER.COM

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Summary of Contents for BTCPower EVPC-150-2-480-3-65

  • Page 1 150kW High Power DC Charger INSTALLATION AND USER’S MANUAL BTCPOWER, INC. 1719 S. GRAND AVE. SANTA ANA, CA 92705 WWW.BTCPOWER.COM...
  • Page 2 This document contains useful general information about the product and its installation. BTCPower, Inc. reserves the right to make changes to this product without 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.

  • Page 3: Table Of Contents

    CCS1 Connector (500 A) ........................39 9.2.3. CCS1 Connector (200 A) ........................39 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.
  • Page 4 Main Parts ............................... 59 Refiling Coolant in Cooling Unit Tank ....................59 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.

  • Page 5: Safety Guidelines

    In situations where it is not possible to perform an installation following the procedures stated in this document, contact BTCPower, Inc. BTCPower, Inc. will not be responsible for any damages that may occur resulting from custom installations that are not stated in this document.

  • Page 6: Symbols And Definitions

    Indicates important information to consider, otherwise, improper installation and/or damage to components may NOTE occur. 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. Revision D...

  • Page 7: System Overview

    (1-DISPENSER SYSTEM): ➢ SIMPLIFIED BLOCK DIAGRAM (2-DISPENSER SYSTEM): ➢ 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. Revision D 10-Dec-20...

  • Page 8: Equipment Description

    7. Air Vent 14. Optical Transceivers * Power Module #4 as optional upgrade 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.
  • Page 9 Charging Connector 1 12. Air Exit (right side) Charging Connector 2 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. Revision D...
  • Page 10 EVDSP-200-5-120-0-2-C-4-0 HPCD1-200-01-003 DCFC 200A Dispenser, Dual CCS EVDSP-200-4-120-0-2-C-4-0 HPCD1-200-02-003 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. Revision D 10-Dec-20...

  • Page 11: System Specification

    IP 54 (NEMA 3R) Specifications are subject to change, without prior notice. 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.

  • Page 12: Dcfc Dispenser

    22“ W x 15” D x 97“ H Weight 600 lbs LED Lighting System 580 lumens 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. Revision D 10-Dec-20...

  • Page 13: Pre-Installation

    Conformance to all governing standards for location and placement of the charger • Communications Connectivity o Refer to BTCPower guidelines in “Determining Suitability of Site for Cellular Connectivity” o Ensure that installation location meets the Cellular Signal Strength Criteria below Parameter...

  • Page 14: Cable Reach

    CCS1 (200A) 13 feet HPCD1-200-02-003 CCS1 (200A) 13 feet 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. Revision D 10-Dec-20...

  • Page 15: Ada Consideration

    The document, Guidance on the 2010 ADA Standards for Accessible Design, can be downloaded from: http://www.ada.gov 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.
  • Page 16 ADA requirements. That includes being under 48” of distance to the ground. 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.

  • Page 17: List Of Parts, Materials, And Tools Needed For Installation

    ½” Torque Wrench Allen Wrench Set Keys (shipped with the unit) 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. Revision D...

  • Page 18: Transportation And Handling

    Refer to section 7.1 for more details. 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.

  • Page 19: Receiving And Unpacking

    Receiving and Unpacking Receiving Instructions Once shipment is received, please follow these receiving instructions. It is the responsibility of the receiver to perform 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 any incidents during its transportation.

  • Page 20: Installation

    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.

  • Page 21: Moving And Hoisting Instructions

    Use eye bolts at a vertical angle of no more than 15°. Eye bolt strength at 15° angle drops down to 80% of vertical lifting capacity. 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.
  • Page 22 INSTALLATION INSTALLATION AND USER’S MANUAL 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 angle between 0° to 15° when lifting.
  • Page 23 POWER BOX / TOWER DISPENSER 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. Revision D...

  • Page 24: Mounting Procedures

    Refer to the installation drawings as illustrated below. Power Box / Tower Installation Drawing 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.

  • Page 25: 7.2.2. Tower And Dispenser Mounting

    3830) concrete expansion bolts or as determined appropriate by the structural engineer in- charge. Make sure to check local codes for compliance. 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.
  • Page 26 NOTE The bottom of the tower needs to be sealed to the ground. 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.
  • Page 27 NOTE The bottom of the dispenser needs to be sealed to the ground. 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.

  • Page 28: Electrical And Communication Service Connection

    1-Tower, 1-Dispenser (350kW) Configuration System 1-Tower, 2-Dispenser (350kW) Configuration System 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. Revision D 10-Dec-20...
  • Page 29 1-Tower, 1-Dispenser (200A) Configuration System 1-Tower, 2-Dispenser (200A) Configuration System 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. Revision D 10-Dec-20...
  • Page 30 Connections to the charger shall comply with all applicable electrical codes and ordinances. 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.
  • Page 31 The system is not phase rotation sensitive, thus there is no concern over the phasing of the termination of the AC Lines. 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.
  • Page 32 Dispenser • Channel B: Use this channel for the 2 Dispenser 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. Revision D...
  • Page 33 (copper or aluminum) NOTE Wire should be 1,000V rated (minimum) and suitable for 500A 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.
  • Page 34 Dispenser Ground – Must have a common direct ground with the Tower 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.
  • Page 35 Fiber Optic Cable Connection Dispenser – Interlock Fiber Optic Cable Connection 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. Revision D...

  • Page 36: Verification And Inspection

    1-855-901-1558. After successful commissioning, email completed commissioning checklist dispatch@btcpower.com. 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. Revision D 10-Dec-20...

  • Page 37: Operation

    • SWITCH ON the circuit breaker inside the Dispenser as shown below. • Then, SWITCH ON the Main Panel Breaker. 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.

  • Page 38: Output Connectors

    • Cable Length : 10.5 ft • Connector Weight : approximate 3.97 lbs. 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. Revision D...

  • Page 39: Ccs1 Connector (500 A)

    9.2.3. CCS1 Connector (200 A) • Cable Length : 13 ft 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. Revision D...

  • Page 40: Operating Instruction

    Displays Payment Options Credit Card, RFID Card Tap RFID Card to Proceed 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.
  • Page 41 Charging Initialization SCREEN 6 Session Details Text Message Option 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. Revision D 10-Dec-20...
  • Page 42 SCREEN 9 End of Charging Unplug Connector and Return to Holder 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. Revision D...

  • Page 43: Troubleshooting

    Temperature of cord delta is not in range. Need tech visit to check cooling system 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.
  • Page 44 Power module losses ready signal Check power module CUBE_DERR_ERROR Charger Tower 4 Medium Power module detects Driver error Report to BTCPower. Mostly it will need tech visit CUBE_AFE_WORKING_REMOVED Charger Tower 4 Medium Power module detects AFE working signal lost If too frequent then report. Maybe it will need field visit.
  • Page 45 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.
  • Page 46 Server or Payment controller took too long to give controller authorization 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. Revision D...
  • Page 47 Payment_Declined User 6 Info User declines the payment 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. Revision D 10-Dec-20...

  • Page 48: Maintenance

    Inspect AC/DC terminations and look for signs of arcing and heat-stress on cables and bussing 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.
  • Page 49 • Tighten all high current connections to its specifications 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. Revision D...
  • Page 50 Please keep in mind that the replacement interval of each part can vary depending on, for example, the usage environment of the device. 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.
  • Page 51 170-0065-01 Hexagonal Rod 170-0066-01 Multi-point Latch/Lock 170-0067-01 Latch Assembly 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. Revision D 10-Dec-20...
  • Page 52 Changes or modifications to this product by other than an authorized service facility could void, warranty, UL and FCC compliance. 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.

  • Page 53: Product Disposal

    INSTALLATION AND USER’S MANUAL 11. Product Disposal BTCPower Inc. carefully considers 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 reduce environmental impact.

  • Page 54: Appendix

    Optional Longer Cable Length Available with Dimension A of 7620 mm or 25 ft 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.

  • Page 55: B) Cooling Unit System

    Part Details Part Number: 190-0113-01 Manufacturer: Huber + Suhner 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. Revision D 10-Dec-20...

  • Page 56: C) Cool Cable Coolant

    *Application Note from supplier on the next page APPENDIX 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.
  • Page 57 150kW High Power DC Charger APPENDIX INSTALLATION AND USER’S MANUAL 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. Revision D...

  • Page 58: D) Sae J1772 Ccs1 Coupler (200A Rated)

    CHAdeMO High Power Coupler (200A Rated) Part Details Part Number: 190-0137-01 Manufacturer: Rema 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. Revision D 10-Dec-20...

  • Page 59: 12.2. Cooling Unit System Overview

    If the cable length used is between the specified cable length in the table, use the less amount of total volume filling. 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.
  • Page 60 Fill 2.9 liters coolant in tank using a funnel or tube • Close tank with plug 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.
  • Page 61 Close tank with filling plug • Cooling unit is ready 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. Revision D...
  • Page 62 Section • Updated the screen flows during charging session. 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. Revision D 10-Dec-20...
  • Page 63 10-Dec-20 • Updated spec section (auxiliary input current) Rosh Dihayco 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. Revision D...

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