FREEWIRE Boost Charger Installation Manual
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FREEWIRE Boost Charger Installation Manual

Dc fast charging station
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Boost Charger
DC Fast Charging Station
™
Installation Guide
Version 1.0

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Summary of Contents for FREEWIRE Boost Charger

  • Page 1 Boost Charger ™ DC Fast Charging Station Installation Guide Version 1.0...
  • Page 2 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 FreeWire® Boost Charger™ in a manner in which it is not intended to be used or modified will void the limited warranty. You should review your warranty and become familiar with the terms thereof.
  • Page 3 Safety and compliance The FreeWire Boost Charger is for Outdoor Use Only and to be mounted on a non-combustible surface such as a concrete pad that extends a minimum of 3 feet beyond the perimeter of the battery system/Boost Charger.

  • Page 4: Table Of Contents

    GENERAL WARNINGS ..........................7 SAFETY SHUTDOWN ..........................7 OVERVIEW ............................8 Boost Charger Components ..........................8 Boost Charger Main Component Overview ...................... 9 Circuit Breakers ................................11 Unlocking and Locking the Front Access Door ....................12 Installation Overview ..............................13 Concrete Pad Installation ............................
  • Page 5 Powering on the Boost Charger ..........................29 Commissioning the Boost Charger ........................30 Complete a Test Charging Session ........................30 BOOST CHARGER SPECIFICATIONS ..................... 32...

  • Page 6: Before You Start

    Boost Charger. An earth ground that complies to local codes must also be used for the Boost Charger and be connected to the equipment grounding terminal or lead on the Electric Vehicle Supply Equipment (EVSE). Connections to the EVSE shall comply with all applicable codes and ordinances.

  • Page 7: General Warnings

    Safety Shutdown The FreeWire Boost Charger can be shut down to disconnect the internal battery from the rest of the system. The red safety shutdown button on the front of the Boost Charger activates the safety shutdown.

  • Page 8: Overview

    Overview To ensure the successful installation of the FreeWire Boost Charger® DC fast charging station, please be sure to read this overview and become familiar 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.

  • Page 9: Boost Charger Main Component Overview

    1 OVERVIEW Boost Charger 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 Cooler/ HVAC Battery Stack...
  • Page 10 1 OVERVIEW 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 Supplies...

  • Page 11: Circuit Breakers

    1 OVERVIEW Low Voltage Battery Battery Management System Cellular Modem Computer Processor Circuit Breakers Breaker Function Main AC contactor AC/DC battery charger 1 4 5 6 AC/DC battery charger 2 Battery air conditioning Liquid cooling system pump 24 V system power supply Computer processor power Battery heaters Located on the upper...

  • Page 12: Unlocking And Locking The Front Access Door

    1 OVERVIEW Unlocking and Locking the Front Access Door In order to unlock/lock the Boost Charger front access door, the locks behind the CHAdeMO and CCS charge cables must be accessible. Step 1 Remove the CHAdeMO charge cable from its respective holder.

  • Page 13: Installation Overview

    Note: Always check local codes and requirements to ensure that the installation is compliant. Concrete Pad Installation The FreeWire Boost Charger must be installed on a concrete pad. Details can be found in the FreeWire Boost Charger Site Preparation Guide (Part Number 770-00004-01). Before proceeding, make sure the conduit is plumb and the concrete pad is properly prepared, free of debris, level, and cured.

  • Page 14: Preparation

    3. Ensure the grounding conductor is properly grounded and complies with local codes. 4. Confirm there is a strong cellular signal available. The Boost Charger requires a cellular network. Install repeaters if the signal is below -110 dBm or if the signal is intermittent. A hard-wired internet connection can be used if there’s no cellular signal available.

  • Page 15: Boost Charger Overall Dimensions

    1 OVERVIEW Boost Charger Crate Packing List • Boost Charger • Door access keys (2x) • Door Tool Boost Charger Overall Dimensions...

  • Page 16: Equipment Needed

    1 OVERVIEW Equipment Needed • Forklift (5,000lb capacity minimum) or crane (5,000lb capacity minimum) with nylon lifting straps and four-point lifting sling • Forklift tyne extensions (as required) • 15/16” wrench and socket • #2 Phillips screwdriver • T27 tamper proof pin-in Torx driver and bit •...

  • Page 17: Installation Of The Boost Charger

    Installation of the Boost Charger The steps outlined in this procedure require the use of a forklift or crane to lift, move, and mount the Boost Charger. A crane setup using a four-point sling, similar to the example pictured to the right, may be used in situations when a forklift cannot be used for installation.

  • Page 18: Uncrating The Boost Charger

    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 crate and remove the side panels. Follow the steps below to uncrate the Boost Charger.
  • Page 19 2 INSTALLATION OF THE BOOST CHARGER 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.
  • Page 20 2 INSTALLATION OF THE BOOST CHARGER Step 5 Using 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.
  • Page 21 2 INSTALLATION OF THE BOOST CHARGER 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.
  • Page 22 2 INSTALLATION OF THE BOOST CHARGER Step 9 Remove the four screws that hold 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 later.
  • Page 23 Remove the four bolts which secure the Boost 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 pad for installation.

  • Page 24: Mounting The Boost Charger

    2 INSTALLATION OF THE BOOST CHARGER Mounting the Boost Charger Step 1 Remove the cap from each of the 8 mounting bolts on the concrete installation pad. Concrete Pad Protective Caps (x8) Mounting Bolts (x8) Conduit Step 2 Using a forklift or crane, slowly lift...
  • Page 25 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 Charger frame. Finally, tighten each nut using the torque wrench to 100 ft lbs.

  • Page 26: Grounding Requirements

    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 the front of the control panel. Either the front panel button or the external switch may be used to initiate a safety shutdown.
  • Page 27 2 INSTALLATION OF THE BOOST CHARGER Step 1 Boost Charger works with a normally closed external safety shutoff 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.

  • Page 28: Connecting Electrical Power

    For 240 V split phase, use Phases A and B plus Neutral as identified in 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.

  • Page 29: Powering On The Boost Charger

    Important: You have now completed the physical installation of the Boost Charger. Follow the steps in the next section to complete the installation. Do not leave the installation site until you have completed all steps in the next section and have verified that the Boost Charger is operating correctly.

  • Page 30: Commissioning The Boost Charger

    2 INSTALLATION OF THE BOOST CHARGER Commissioning the Boost Charger The FreeWire Boost Charger uses EV Connect to allow drivers to easily find, access, and securely pay for EV charging. Drivers can search for and locate electric vehicle charging stations based on location, station ID, availability, power level provided, and accessibility.
  • Page 31 If the Boost Charger operates 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 Charger is properly wired, but is not operating correctly, contact FreeWire...

  • Page 32: Boost Charger Specifications

    3 BOOST CHARGER SPECIFICATIONS Boost Charger Specifications System CHAdeMO: 100 kW Max Output Power CCS: 120 kW Combined: charge two vehicles up to 60 kW each CHAdeMO: 200 A Max Output Current CCS: 300 A Dimensions 40 in x 43 in x 96 in...
  • Page 33 NOTES Safety and Compliance U.S.: complies with UL 2202, UL 2231-1, UL 2231-2, UL 991, Safety Compliance UL 1973 (battery pack) EMC Compliance U.S.: FCC part 15 Class A Safety: Electric Vehicle • See the EV supplier’s guide for proper care of the EV and follow directions carefully. Failure to follow EV care instructions can results in EV explosion and property damage, severe injury, or death during charging.
  • Page 34 Any additional 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...

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