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Free2Move eSolutions DC Series User's Manual & Installation Instructions

180kw standalone fast charger
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DC Series
DC EVSE 180kW
Standalone Fast Charger
User Manual & Installation Instructions
UL
Model
Copyright© 2024 by Zerova. All rights reserved.

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  • Page 1 DC Series DC EVSE 180kW Standalone Fast Charger User Manual & Installation Instructions Model Copyright© 2024 by Zerova. All rights reserved.

  • Page 2: Table Of Contents

    Contents 1. Specifications and Features ...............2 1.1 Device User Interface ................2 1.2 Product Specifications ................. 3 1.3 Dimensions ................... 8 1.4 Airflow Direction .................. 8 1.5 Detailed View of Charger ..............9 1.6 Version Description ................10 2. Unpacking and Moving ..............11 3.
  • Page 3 Revision History Author Version Date Description Writer Editor V1.0 2024/04/01 V2.0 2024/05/13 • Free2Move customized first issue Natalie Julie...
  • Page 4 Introduction The intent of this manual is to provide a guide for the installation of the Standalone DC Fast Charger. The owner/operator of the charger is responsible for contracting an installer, and must make sure that all national/local codes, laws, and regulations are complied with during the installation. Compliance with the information in this manual does NOT relieve the owner/ operator of their responsibility tocomply with all applicable codes and safety standards.

  • Page 5: Specifications And Features

    1. Specifications and Features 1.1 Device User Interface Antenna for Wi-Fi & 3G/4G LED Indication 7" Information Screen • Charging Status • Alarm information • User Authorization Right Button & Left Button RFID Capable Credit Card Payment System (If equipped) Emergency Stop Left DC Charging Plug...

  • Page 6: Product Specifications

    1.2 Product Specifications DS180 Series Voltage Rating 3Φ480Vac (+10%, -15%) Input Current 233A@180kW Electrical Distribution 3P+ N+ PE (Wye configuration) Power Grid System TN/TT Frequency 50/60Hz Input Max. Input Power 196kVA Power Factor > 0.99 at full load Efficiency > 94%, at optimize V/I point SCCR 65kA DC 150 ~ 950V (CCS)
  • Page 7 OTP, AC contactor detection, DC contactor detection, Internal Protection Fuse detection Load Management Via OCCP 1.6/2.0 JSON Display 7-inch LCD Right Button: Connector Select Button Left Button: Home / Stop Charge. User Interface and RFID: Support ISO 14443A/B, Control ISO 15693, FeliCa Lite-S User Authentication (RCS966),Backend OCPP: 2D barcode, APP, Mobile Payment,...
  • Page 8 31.5 × 25.6 × 74.8 in. (800 × Dimensions LxWxH 650 × 1900 mm) <500kg (1102 lbs) with two Weight (typ.) charging connectors Mechanical DC Charging See Table 4 Specifications Connector Cooling Fan Cooling Ingression Protection NEMA 3R IK10, excluding LCD & RFID Anti-vandalism cover *¹...
  • Page 9 Table 1 Maximum Output Current Connector 180kW Code 200A@150Vdc ~ 900Vdc when CCS1 200A output voltage up to 950Vdc the output current is 189A 300A@150Vdc ~ 600Vdc when output voltage up to 950Vdc the CCS1 300A output current is 189A 300A@150Vdc ~ 600Vdc when CCS1 300A output voltage up to 950Vdc the...
  • Page 10 Table 2 Dynamic Sharing Output mode DS180 : 180kW 雙槍動態分配 DS180 Group 2 Group 3 PSU 3 PSU 5 60kW 60kW PSU 2 PSU 6 Group 4 Group 1 30kW 30kW PSU 1 PSU 4 Output Relays Bridge Relays Left Plug Right Plug Left Plug Right Plug...

  • Page 11: Dimensions

    1.3 Dimensions Unit: mm 2.62ft (800m) 2.13ft (650m) Figure 2. Dimensions 1.4 Airflow Direction Air In Air Out Note: Standard and ADA cabinet share the same direction. Figure 3. Airflow Direction 8 DC EVSE Standalone DC Fast Charger...

  • Page 12: Detailed View Of Charger

    1.5 Detailed View of Charger DC contactor CSU 3.0 Board Fan Control board Relay controler board Emergency X1. X3. X4 Button connector panel Assistant switch EMI Box (optional) Breaker AC Contactor Display Push Botton RFID Emergency Button LED Control board Figure 4.

  • Page 13: Version Description

    1.6 Version Description The DS90-DS180 series is available in many different configurations. See Table 4 for available model numbers and their corresponding features. Version Left DC Connector Right DC Connector DSWA182J0I CHAdeMO CCS1 DSWA182I00 CCS1 DSWA182I0I CCS1 CCS1 Table 4. Version Number Features NOTE The letter “X”...

  • Page 14: Unpacking And Moving

    2. Unpacking and Moving The EVSE will be delivered on a pallet to a warehouse or specified location. Transportation to the final destination is the responsibility of the customer / contractor. Damage to the packaging caused by tilting, falling, or impact during transportation can cause damage or defects.
  • Page 15 1) Remove the wooden sides of the package. See Figure 5. Figure 5. Unboxing 1 2) Remove the carton, packing cushion, and film. See Figure 6. Figure 6. Unboxing 2 3) Remove the 4 M10 bolts that attach the EVSE to the pallet. See Figure 7. Figure 7.
  • Page 16 4) To move the EVSE using a crane, attach a bridle hitch with four legs to the eye bolts using ¼ in. (6mm) diameter steel cables. Each leg of the hitch should be 31.5 in. (800mm) in length. See Figure 8. Figure 8.

  • Page 17: Installation

    3. Installation 3.1 Warnings, Cautions and Notes WARNING Do not use this product if the power or charging cable is damaged. WARNING Do not use this product if the enclosure or charging connector is broken, damaged, or open. WARNING Do not put any tools, materials, fingers, or other body parts into the charger or EV connector.
  • Page 18 277V 277V 480V Neutral 277V Figure 10. 480V Three-Phase Wiring Connection CAUTION The EVSE should be installed in an area with free-flowing air. CAUTION The disconnect switch for each ungrounded conductor of AC input shall be provided by installation contractor or technician in accordance with the National Code, ANSI/NFPA 70.
  • Page 19 3.1.1 Contractor Safety Guide Introduction • A safe work environment for everyone - participants, installation and demolition crews, contractors and subcontractors. • Ultimately, it is the responsibility of contractors to ensure the safety and safe work practices of their employees and subcontractors who may be working at the site on their behalf.
  • Page 20 1.Requirements for workplace conditions • Set up suitable fencing to isolate the construction area from outside • Close and secure all entrances when the site is unattended • Hang warning notices nearby which show the following information: warning icon and phone number of person in charge •...
  • Page 21 4.Protection against high temperatures on the worksite • Erect a sunshade or shed to shelter workers from the heat and sun • Set up cooling equipment, such as exhaust fans • Make water dispensers available • Provide suitable protective clothing such as hat, sunglasses and long sleeves to protect workers from heat stroke and UV rays 5.Inclement weather  ...
  • Page 22 • protection equipment for workers • Use non-conductive ladders made of glass- fiber or reinforced plastic when carrying out electrical work • Assign assistants to provide support when working on ladders • Check all ladders for broken rungs or other defects before use and periodically •...
  • Page 23 8.Lifting operations • Have lifting gear and apparatus regularly inspected and tested by qualified persons • Isolate and cordon off lifting areas to keep out non-construction personnel • Ensure that lifting routes do not cross buildings or people, and avoid collision with objects •...

  • Page 24: Required Area For Placing And Maintaining

    3.2 Required area for placing and maintaining. See Figure 11. Required a space of 104.33in x 110.23in (2650mm x 2800mm). This space is calculated as follows: • EVSE Size: W = 25.6in (650mm) × D = 31.5in (800mm) × H = 74.8in (1900mm). •...

  • Page 25: Tools And Materials

    3.3 Tools and Materials Type Description Philips Screwdriver No. 2 and 3 Adjustable Wrench Socket Wrench 8mm, 10mm, 17mm, and 18mm Electrical Tape Black / 15mm (0.6 in.) Width Crimping Pliers for Ring Hexagonal Terminal Wire Stripper Wire Cutters Crane / Forklift 1102 lbs (500kg) minimum Cable gland Waterproof sealing glue...

  • Page 26: Building The Evse Base

    3.4 Building the EVSE Base See Figure 12 and Figure 13. 1) Build a level concrete base with the following minimum dimensions: • Area: 42.91in (1090mm) × 29.52in (750mm) • Height : 7.87in (200mm) 2) Install a PVC AC cable conduit smaller than Ø4.02in (Ø102mm) 3) Install a PVC SFTP Ethernet cable conduit smaller than Ø1.34in (Ø...
  • Page 27 6) Extend the 3 phase 5 wire AC input cables from conduit of concrete base. See Figure 13. • AC Cables: At least 350kcmil (177mm²) width for L1, L2, L3, N, and 4AWG (21.15mm²) for PE. Include ring terminals with a diameter of 0.41 in. (10.5mm) for L1, L2, L3, N, 0.33in (8.4mm) for PE.

  • Page 28: Securing The Evse (Method 1)

    3.5 Securing the EVSE (Method 1) METHOD 1. 1) Lift the charger over the concrete base. See Figure 14. Figure 14. EVSE Placement 2) Pull the input cables through the bottom hole of the charger. 3) Attach 4 washer and 8 nuts (2 each) to the 4 M12 threaded rods. See Figure 15. Figure 15.

  • Page 29: Securing The Evse (Method 2)

    4) Attach the base cover (in the accessory pack) to the EVSE. See Figure 16 Figure 16. Base Cover Install 3.6 Securing the EVSE (Method 2) 1) Attach the L-brackets using 6 M12 expansion bolts. See Figure 17. Figure 17. L-Bracket Install NOTE If the eye bolts on top of the cabinet are removed, the plastic bolts (from the accessory pack) must be installed using waterproof sealant.

  • Page 30: Cable Installation

    3.7 Cable Installation 1) Open the door and remove the protective cover for the wiring. See Figure 19. Figure 19. Cable Gland 2) Cut and strip AC cables according to requirement. Clamp ring terminals on AC cables. 3) Connect AC cables L1, L2, L3 and N to the busbars (See Figure 20). Attach each wire and torque the fasteners according to "Appendix 2 - Torque Requirements Table".

  • Page 31: Seal The Cable Entry Hole

    Without EMI Box With EMI Box Figure 20. Cable Connection 3.8 Seal the cable entry hole The cable entry hole needs to be sealed to maintain an IP55 rating for the EVSE. 1) Seal the hole with flame retardant material and electrical insulating foam or another sufficientmethod.
  • Page 32 NOTE The SOR circuit breaker should have a maximum withstand voltage of 277Vac Door Sensor Signal Upstream Circuit Breaker Sensor Board Similar Safety Device Tilt Sensor Figure 21. Functional Block Diagram 3.10 Connecting the Sensor Board See Figure 22. Figure 22 Sensor Board Connectors 3.11 Wire Specifications 1) Connect UL1015 22AWG 105°C 600V wires from the sensor board to the upstream circuit breaker.
  • Page 33 3.12 Breaker Lock Removal 1) Locate the breaker lock. See Figure 24. Figure 24. Breaker Unlock 2) Turn the lock key to unlock and remove the lock. See Figure 25 and Figure 26. Figure 25. Breaker Unlock 30 DC EVSE Standalone DC Fast Charger...
  • Page 34 Figure 26. Lock Removal 3) Open the flap to locate the knob. See Figure 27. Figure 27. Lock Flap Open DC EVSE Standalone DC Fast Charger 31...
  • Page 35 4) Turn the knob counter-clockwise and remove the breaker lock. See Figure 28, Figure 29, and Figure 30. Figure 28. Turn Knob Figure 29. Remove Lock Flap 32 DC EVSE Standalone DC Fast Charger...
  • Page 36 Figure 30. Breaker Unlock DC EVSE Standalone DC Fast Charger 33...

  • Page 37: Setup

    4. Setup 4.1 Laptop Setup Requirements: • A laptop with a wireless Internet connection and an RJ45 port. • Connect an RJ45 cable. See Figure 31. • Laptop IPV4 static IP address set to 192.168.1.1. See Figure 32. Figure 31. RJ-45 Port Use the following IP address: IP address: 192.

  • Page 38: Login To The Evse

    4.2 Login to the EVSE 1) In a web browser, navigate to 192.168.1.10. 2) See Figure 33. On the EVSE Homepage, login with the credentials that follow: • Account: admin • Password: 1231231238 192.168.1.10 login https://192.168.1.10 Account admin Password 1231231238 Figure 33.
  • Page 39 3)Select Wi-Fi modes and fill in the SSID and Password, according to your requirements. See Figure 36. Wi-Fi Setting Description 192.168.1.10 UPGRADE OTHER LANGUAGE Enable(station) or disable or Mode WiFI Module set as AP mode Mode SSID Service Set Identifier SSID SSID Password Password to access to Wi-Fi...

  • Page 40: Sim Card Installation

    4.4 SIM Card Installation 1) Pull out the top tray from the CSU box to access the 4G/Wi-Fi module inside the cabinet. See Figure 37. Figure 37. 4G/Wi-Fi Module Access 2) Insert a 3G/4G Micro SIM Card in the tray, make sure the gold contacts are facing down andthe notch is in the upper right corner.

  • Page 41: 4G Network Setup

    4.5 3G/4G Network Setup 1) Contact your SIM provider and get the APN, PPP ID, and password. NOTE The PPID ID and password option may depend on your SIM provider. 2) Setup the laptop per 4.1, as needed. 3) Login to the EVSE per 4.2, as needed. 4) Select: SET | Network | 3G/4G.

  • Page 42: Time Settings

    4.6 Time Settings Automatic setting: The time will be adjusted automatically when the EVSE connects to the internet. Possible time servers: • time.windows.com • cn.ntp.org.cn • tock.stdtime.gov.tw NOTE Firewall and network environment may influence the time server connection. Manual setting. 1) Setup the laptop per 4.1, as needed.
  • Page 43 5) Select SET and wait until the seeing completion window appears. See Figure 43. 192.168.1.10 System System Information System DateTime XXXX-XX-XX XX:XX:XX XXXX-XX-XX XX:XX:XX Figure 43. Set Date/Time 40 DC EVSE Standalone DC Fast Charger...

  • Page 44: Installation Inspection And Commissioning

    5. Installation Inspection and Commissioning 5.1 Environmental Check Item Status Remark Ambient Temperature Ambient Humidity Sunshade Recommended but not required. Recommended for better charging Rain Canopy experience and maintenance on rainy day. Installation Altitude <= 2000m (6560 ft) Air Circulation / Drafty Dust Level Anti-Vandalism Measures...

  • Page 45: Evse Check - Power On

    5.3 EVSE Check - Power On WARNING Improper connection of the EVSE grounding conductor can result in a risk of electric shock. Make sure the EVSE is properly grounded prior to energizing. Item Status Remark Power On Screen On Acoustic Noise Screen Display &...

  • Page 46: Evse Check - Charging

    5.4 EVSE Check - Charging Item Status Remark User Authorization - RFID User Authorization - QR Code User Authorization - Others Waiting Time of Connection Check vReading of Each Display Item Full Charge Test Temperature Readings Function of Electronic Lock Reading of Engineer Mode Airflow &...

  • Page 47: Appendix A - Package List

    6. Appendix A - Package List Item Description Remark EVSE User manual EVSE Approved certificate OQC Report RFID Card Door Key Base cover M4x8 screw Breaker Lock Waterproof Plastic Bolts Cable Management Optional Screws for R/S/T/N busbars 1 kit 44 DC EVSE Standalone DC Fast Charger...

  • Page 48: Appendix B - Torque Requirements Table

    7. Appendix B - Torque Requirements Table Steel Steel Steel Aluminum Aluminum Metric Size Type lbf-in Kg-cm Kgf-cm M2*0.4 Machine 3~4.77 3.5~5.5 0.34~0.54 3~4.5 0.34~0.44 M2.5*0.45 Machine 3~4.77 3.5~5.5 0.34~0.54 3~4.5 0.34~0.44 M3*0.5 Machine 5.5~9 6.5~10.5 0.64~1.04 5.2~8.4 0.51~0.82 M3.5*0.6 Machine 8.5~13 10~15...

  • Page 49: Appendix C - Preventive Maintenance Check List

    8. Appendix C - Preventive Maintenance Check List Item Description year year year year year year Preventive maintenance Appearance Appearance visual inspection inspection Fan clean and spinning 3 System fan smoothly check Air filter, air inlet and 4 Air filter outlet clean 5 Charging cable Appearance clean 6 PCBA...
  • Page 50 NOTE DC EVSE Standalone DC Fast Charger 47...
  • Page 51 NOTE 48 DC EVSE Standalone DC Fast Charger...
  • Page 52 NOTE DC EVSE Standalone DC Fast Charger 49...
  • Page 53 Manufacturer Contact Info Sticker 50 DC EVSE Standalone DC Fast Charger DC EVSE Standalone DC Fast Charger 50...

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