BTCPower EVP-FC-25-001 Manual

BTCPower DC Fast Charger
Installation and Maintenance Manual
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 1 of 22
160186-Staff-POD-9-11

PLEASE NOTE
This user’s manual includes the latest information at the time of printing. BTCP reserves the right
to make changes to this product without further notice. Changes or modifications to this product
by other than an authorized service facility could void the product warranty.
If you have questions about the use of this product, contact your customer service representative.
This product is should be operated by trained personnel only.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 2 of 22
BTCPower DC Fast Charger Installation and Maintenance
Manual
Revision History
Rev
Date
ENC#
Description of BTCP EVSE
Originator
A
12/26/2012
1001
Initial Release
David Hymel
B
4/10/2014
David Hymel
C
4/24/2014
David
Hymel
D
7/24/2014
Safety Instructions
added
Jeannie Yoo
E
1/30/2015
Added 480VAC, 50KW
David
Hymel
160186-Staff-POD-9-12

Table of Contents
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 3 of 22
Part Description Page
1. SAFETY 4
1.1 Important safety instructions 4
1.2 Symbols and Definitions 5
1.3 Dangers and Cautions 6
1.3.1 Operations 6
1.3.2 Maintenance 6
1.3.3 Installation 6-7
1.4 Charge system description 8
2. INSTALLATION 9
2.1 ADA considerations and access to system 9
2.2 Choosing a suitable location 9
2.3 Electrical Service Connection 10
2.4 480 VAC electrical service connection 11
3. OPERATION 15
3.1 Charging session and operation procedure 15-16
3.2 Stop procedure 17
3.3 Time Out 18
4. TROUBLESHOOTING 19
5. MAINTENANCE 20
5.1 Maintenance Precautions 20
5.2 Maintenance Items 20
5.3 Visual Check Items 20
5.4 Replacement of Fixed-Life Components 20
6. WARRANTY INFORMATION 21-22
160186-Staff-POD-9-13

SAVE THESE INSTRUCTIONS
This manual contains important instructions for DC Fast Charger that shall be followed during
installation, operation and maintenance of the unit
1. SAFETY
1.1 Important Safety Instructions
WARNING ELECTRIAL DANGER –PLEASE READ
READ THIS MANUAL BEFORE YOU BEGIN
EVSE (Electric Vehicle Supply Equipment) manages electricity and may be hazardous. Failure to follow
the below precautions and the Danger, Warning and Caution instructions in this manual may result in
serious injury. Follow all rules, codes and laws that apply to your area and installation guidelines.
This equipment should be installed, adjusted and serviced by qualified electrical personnel familiar
with the construction and operation of this type of equipment and the hazards involved. Failure to
observe this precaution could result in death or severe injury.
Read this manual completely prior to installation and energizing the equipment. Inspection and
maintenance of this equipment should be performed in accordance with the operating procedures
detailed in this manual
The purpose of this manual is to provide you with information necessary to safely operate, maintain,
and troubleshoot this equipment. Keep this manual for future reference.
DO NOT use this product if the EV cable is damaged in any way, cracked or open insulation or any
other sign of wear.
THE INFORMATION CONTAINED WITHIN THIS MANUAL IS SUBJECT TO CHANGE WITHOUT NOTICE.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 4 of 22
160186-Staff-POD-9-14

1.2 Symbols and Definitions
The following symbols may be found in your handbook or on labels affixed to your conductive charge
station:
ELECTRICAL
WARNING
This symbol indicates high voltage. It calls your
attention to items or operations that could be
dangerous to you and other persons operating this
equipment. Read the message and follow the
instructions carefully failure to do so may result in
severe injury or possibly death.
WARNING
Warning indicates a hazard or unsafe situation which,
if not avoided, may result in severe injury or possibly
death.
CAUTION
Caution indicates a hazard or unsafe practice which, if
not avoided, may result in minor injury
NOTE
Important information to consider, otherwise,
improper installation and/or damage to components
may occur.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 5 of 22
160186-Staff-POD-9-15

1.3 Dangers and Cautions
1.3.1 Operation Warnings
Use this charge station to charge electric vehicles equipped with CHAdeMO or SAE charge port
connectors only. To determine if your vehicle is equipped with one please review the vehicle’s
owner’s handbook.
When installing the equipment and during regular operation, please ensure the charge station’s
supply cable is located in such a way that the cable will not be tripped over, stepped on, pulled on, or
somehow subjected to damage or stress during normal operation or while stored.
1.3.2 Maintenance Warnings
WARNING
There are no user serviceable parts inside. For service please contact customer service or your local
distributor. DO NOT ATTEMPT TO REPAIR THE CHARGE STATION YOURSELF ONLY FACTORY
QUALIFIED PERSONNEL.
WARNING
If your supply cable is somehow damaged do not operate your charge station. Contact your service
representative for service immediately. Shut down the power to the unit by switching the breaker on
the supply panel to the off position.
WARNING
Turn off input power to your charge station at the circuit breaker panel before servicing or cleaning
the unit.
CAUTION
Do not charge your vehicle indoors if it requires ventilation. Contact your Service representative for
information.
1.3.3 Installation Warnings
The EVSE (Electric vehicle supply equipment) should be installed by a qualified electrician in
accordance with local codes and all applicable ordinances
WARNING
This unit is not intended to be used in a commercial garage (repair facility) or closer than 20 feet (508
mm) of an outdoor motor fuel dispensing device.
The charging station is required to be connected to a ground, metal, permanent wiring system.
Connections to the charge station should comply with all local codes and ordinances.
Read all installations instructions carefully prior to performing the installation.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 6 of 22
160186-Staff-POD-9-16

1.3.3 Installation Warnings - Continued
WARNING
•Charger may be installed outdoors but only use under environments specified within this
specification.
•Only qualified personnel should work on this equipment.
•Do not perform any live wire operations.
•Only qualified skilled in electric services personnel shall perform maintenance checks.
•DO NOT touch the inside of the device while it is running.
WARNING
•This device includes capacitive components such as electrolytic capacitors. Some parts still
remain charged inside of the unit even after the input power is disconnected.
•This device utilizes high voltages do not attempt to install this equipment if you are not a qualified
electrician.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 7 of 22
160186-Staff-POD-9-17

1.4 Charger System Descriptions
Part Names and Functions
1
2
3
4
5
6
8
9
10
11
7
1. Layard Cord Retractor
2. 15” Outdoor Rated Touch Screen Display
•Displays operating states, charging
time, charging instructions.
3. Encrypted Insert Card Reader
4. Emergency Stop Button
•To be used in an emergency
situation to shut down the device.
5. High Security Lock
6. Charging Coupler
•CHAdeMO or SAE Combo
7. Air Cooling Vent
8. LED Lights
9. Stop Button
•Use to stop charging incase display
malfunctions.
10. Start Button
•Use to start charging incase
display malfunctions.
11. Charging Coupler
•CHAdeMO or SAE Combo
Specifications
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 8 of 22
Model
EVP-FC-25-001 EVP-FC-50-001
Power Rating
25kW 50kW 50kW
Connectors
CHAdeMO and/or SAEJ1772 Combo
Network
Credit Cards accepted (Visa, Master, Discover, AMX)
Input Power
208 VAC 3-Phase 208 VAC, 3-Phase 480 VAC 3-Phase
Input Power Breaker
100A 200A 100A
Efficiency Rating
>90% >90%
Max. Output DC Current
52A 100A
Max. Output DC Voltage
50-500V
Plug
-Out Detection Power terminated per SAE J1772 specifications
Surge Protection
6000 VAC
Ambient Condition
-20°C to +50°C, 95% humidity, 6000ft altitude.
Dimensions
38"w, 72.75"h, 27.6"d 43"w, 72.75"h, 32.25"d
Safety Compliance
ETL Listed for USA and Canada; Complies with UL 2594, UL 2231
-1, UL2231-
2, NEC Article 625,
ADA Compliant
160186-Staff-POD-9-18

2. INSTALLATION
2.1 ADA Considerations
STANDARDS FOR ACCESSIBLE DESIGN for Americans with Disabilities is applicable when choosing the
location and placement of all Electric Vehicle Supply Equipment. The following is a direct excerpt
from the 2010 ADA Standards for Accessible Design:
http://www.ada.gov/2010ADAstandards_index.htm
“The Department of Justice published revised regulations for Titles II and III of the Americans with
Disabilities Act of 1990 “ADA” in the Federal Register on September 15, 2010. These regulations
adopted revised, enforceable accessibility standards called the 2010 ADA Standards for Accessible
Design “2010 Standards” or “Standards”. The 2010 Standards set minimum requirements – both
scoping and technical -- for newly designed and constructed or altered State and local government
facilities, 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 Title II entities that
choose to make structural changes to existing facilities to meet their program accessibility
requirements; and it establishes a similar reference for Title III entities undertaking readily achievable
barrier removal.
The Department has assembled this online version of the official 2010 Standards to increase its ease
of use. This version includes:
2010 Standards for State and Local Government Facilities Title II
2010 Standards for Public Accommodations and Commercial Facilities Title III
The Department has assembled into a separate publication the revised regulation guidance that
applies to the Standards. The Department included guidance in its revised ADA regulations published
on September 15, 2010. This guidance provides detailed information about the Department’s
adoption of the 2010 Standards including changes to the Standards, the reasoning behind those
changes, and responses to public comments received on these topics. The document, Guidance on
the 2010 ADA Standards for Accessible Design, can be downloaded from:
http://www.ada.gov
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
Information Line at 800- 514-0301 (Voice) or 800-514-0383 (TTY).”
2.2 Choosing a Suitable Location
The following should be considered before choosing a location to install the charger:
•2010 Standards for Accessible Design
•Municipality/Government standards for placement of Electric Vehicle Supply Equipment
•Wiring and conduit needed to connect the EVSE to the circuit panel
•Location of vehicle charging inlets while parked
•Use of protective bollards and wheel stops to protect the EVSE
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 9 of 22
160186-Staff-POD-9-19

2.3 Electrical Service Connections
CAUTION
This is a three-phase 208 VAC EVSE charger or 480 VAC EVSE charger.
The BTCP EV Fast Charger includes over current protection as required by the National Electric Code
and has an integrated UL listed 200 Amp breaker for 50KW (208VAC) unit and 100 Amp breaker for
25KW (208 VAC) and for 50KW (480 VAC) unit. Please refer to NEC Article 625 for installation
requirements and check in the installed jurisdiction for any other electrical requirements.
GFCI on panel maybe required if not included in the charge station.
Conduit is to be routed per NEC code standards
Installing the wires
GROUNDING INSTRUCTIONS –This unit is to be connected to a grounded, metal, permanent wiring
system; or an equipment-grounding conductor is to be run with circuit conductors and connected to
equipment-grounding terminal or lead on battery charger. Connections to the charger shall comply
with all local codes and ordinances.
WARNING
Lockout / tagout all electrical source circuits feeding the units in the open position before beginning
wiring or terminations. Failure to follow the instructions could result in severe bodily injury or death.
WARNING
The unit is designed for indoor or outdoor installation. If this unit is mounted outdoors, the hardware
for connecting the conduits to the unit must be rated for outdoor installation and be installed
properly to maintain the proper outdoor / rain tight rating of the enclosure.
Once the enclosure has been situated in its installation location.
*Line 1, Line 2, Line 3, and Ground wires are required, neutral is not required.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 10 of 22
25KW Charger 208VAC 3Phase
Input
50KW Charger 480VAC 3Phase Input
50KW Charger 208VAC 3Phase Input
3 AWG Line for each phase
3/0 AWG Line for each phase
3 AWG GROUND wire
3/0 AWG GROUND wire
CAUTION
For 208 VAC equipment the phases used must each measure 120VAC to Neutral. Earth Ground must
be connected to Neutral at only one point, usually at the Service Entry Breaker Panel.
CAUTION
The electrical connection to the BTCP requires four wires. Three 120 VAC lines and a ground wire.
160186-Staff-POD-9-20

2.4 Electrical Service Connection 480 VAC 3 Phase 50 KW DC Fast Charger
CAUTION
480 VAC EVSE charger.
The BTCP 50 KW, 480 VAC 3 Phase input EV Fast Charger includes over current protection as required
by the National Electric Code and has an integrated UL listed 100 Amp breaker for 50KW
(480VAC). Please refer to NEC Article 625 for installation requirements and check in the installed
jurisdiction for any other electrical requirements.
GFCI on panel maybe required if not included in the charge station.
Conduit is to be routed per NEC code standards
Electrical Connection
Connect 3 phase 480 VAC to Mersen MPDB67013 terminal block. Located in lower DC Fast Charger
compartment. Each phase to ground should measure 277 VAC to ground.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 11 of 22
Mersen Terminal Block
Ground terminal
Main control Power ON
160186-Staff-POD-9-21

2.5 Mounting Procedures
Tools and ancillary equipment
1. Philips head screw driver.
2. QTY 4, ½” x 4” concrete expansion bolts.
3. ½‘” torque wrench.
4. 3/16” allen wrench for electrical connections.
5. Keys (shipped with unit), to be used to open the access panels.
Concrete pad installation requirements.
Use 4 (minimum 4) 1/2” x 4” (PN RHPA-3830) concrete expansion bolts to anchor the steel pedestal
provided with the BTCP EV Charging Station.
WARNING
BTCP EV Charging Station can only be installed onto undamaged concrete slab.
A minimum of 4 expansion bolts should be mounted on the bottom enclosure footer.
In order to install the expansion bolts please follow the following steps:
Installation Steps
1. Drill a hole at the proper drill bit diameter (5/8”). Clean hole thoroughly
PLEASE NOTE: Drill depth required is 3.5 inches.
WARNING
If the drill length is less than specified then bolt will bottom out prior to engaging the bottom
installation footer on the BTCP EV charging station. The system will be able to be rocked or
moved.
2. Insert the expansion bolt sleeve entirely in the hole without the fixture as shown in fig. 2 above.
3. Position the fixture to be anchored, twist the expansion bolt until it is flush with the fixture. Place
enclosure.
4. Tighten the expansion bolt to the specified installation torque.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 11 of 22
160186-Staff-POD-9-22

BTCP EV CHARGING STATION is provisioned to receive an electrical power connection from one of
two locations.
Option 1: Bottom of the enclosure.
Option 2: Rear of the enclosure through a liquid tight fitting.
Figure 1.
EVSE Side view
•Refer to all applicable codes.
•Electrical conduit through the
bottom of enclosure
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 12 of 22
160186-Staff-POD-9-23

Figure 2.
•Rear electrical conduit entry
•2.5” electrical conduit through
rear of enclosure.
Figure 3.
•Conduit Box
OPTION 2: ELECTRICAL WIRING REAR CONNECTION.
In cases where the concrete cannot be trenched an electrical connection into the enclosure can be
made via the hole provided on the right hand side of the enclosure as shown in Figure 2 & 3.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 13 of 22
160186-Staff-POD-9-24

NOTE:
For testing purposes only the BTCP EV Charge Station has been fitted with an entry point on
the top of the enclosure. This modification voids the NEMA 3 design of the cabinet and
should not be installed outdoors.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 14 of 22
160186-Staff-POD-9-25

3. OPERATIONS
3.1 Charging session and operation procedure
Screen 1
Screen 2
Screen 3
Screen 4
Screen 5
Screen 6
Touch here for
SAE Combo
Touch here for
CHAdeMO
Charger Status
Screen 1
Welcome Screen.
Choose your connector:
CHAdeMO or SAE Combo
Screen 2
Insert Credit Card to begin
charge session.
Screen 3
Receipt via text message?
YES –Go to screen 4
NO –Go to screen 5
Screen 4
Enter the phone number
and touch “Enter”
Screen 5
Your card will be charged $X
Select “ACCEPT” to
continue.
Screen 6
Confirm connector is
connected properly.
Select “YES” to continue.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
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permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 15 of 22
160186-Staff-POD-9-26

3.1 Charging session and operation procedure –Continued
Screen 7
Screen 8
Screen 9
Screen 10
Screen 11
Screen 12
Screen 7
Press “START” to begin your
charge session.
Screen 8
Charger checks
communication to the
vehicle.
Screen 9
Charger runs self diagnostic
test to make sure
everything is ok before it
begins to charge a vehicle.
Screen 10
Charging in Process
Current charging info
displayed.
To stop charging, press
“STOP”
Screen 11
Once charge session is
complete, we ask to
disconnect the connector
from the vehicle.
Screen 12
Charging End.
Press STOP to
Stop charging
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
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permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 16 of 22
160186-Staff-POD-9-27

3.2 Stop Procedure.
BTCP EV Charging Station offers 3 ways to stop the charging session.
Option 1. Press STOP on the touch screen
Press STOP on the screen
Option 2. Press STOP Button on the Charger
Option 3. Press the EMERGENCY STOP Button
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 17 of 22
160186-Staff-POD-9-28

3.3 Time Outs
If for any reason the charge session does not begin within 60 seconds after payment has been
processed, CHARGING FAILED screen will display and the credit card transaction gets automatically
voided.
In situations like this, user will need to unplug the connector and re-plug before retry.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
written
permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 18 of 22
160186-Staff-POD-9-29

4. TROUBLESHOOTING
If an error occurs, check the nature of the error by referring to following “Error Code List” and take
appropriate actions according to the on-screen instructions.
This document is Property of BTCPower, Inc. and should
not be copied, reproduced, or used as the basis for sale
or manufacture of apparatus without
BTCPower's
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permission
BTCP EV Fast Charger Installation Manual
Rev D
Page 19 of 22
Error Code
Message
Description
Change
100
No MCU Communication
This is an application fault.
As soon as system resumes, the fault is
cleared.
110
Card ready not available
This is an application fault.
As soon as system resumes, the fault is
cleared.
120
No internet network
This is an application fault.
As soon as system resumes, the fault is
cleared.
200
Not ready from PCM
This is a hard fault that results in “out of
service”
Press STOP and then START to restart the
application to clear the fault
210
Safety Error
Please turn E
-
STOP knob to remove error.
If fails to start on 2nd attempt, call to
customer service no.
Please turn E
-STOP knob to Enable
Charger. If fails to start on 2nd attempt call
to customer service no.
220
Over voltage
This is a hard fault that results in “out of
service”
Press STOP and then START to restart the
application to clear the fault
230
Over current
This is a hard fault that results in “out of
service”
Press STOP and then START to restart the
application to clear the fault
240
Over temperature
This is a hard fault that results in “out of
service”
Press STOP and then START to restart the
application to clear the fault
260
Charger door is open
Front or side door is not completely closed
Please close the door and try again...
270
Emergency Stop
Please turn ESTOP knob to remove error.
Please turn E
-
STOP knob to Enable Charger
300
Over voltage from
vehicle
This error is generated by the vehicle and
results in termination of the charge.
Contact Customer Service
310
Under voltage from
vehicle
This error is generated by the vehicle and
results in termination of the charge.
Contact Customer Service
320
Current deviation from
vehicle
This error is generated by the vehicle and
results in termination of the charge.
Contact Customer Service
330
High battery
temperature
This error is generated by the vehicle and
results in termination of the charge.
Suspend charging for a time
340
Voltage deviation error
This error is generated by the vehicle and
results in termination of the charge.
Contact Customer Service
250
No CAN communication
Most likely the charge connector is
improperly placed.
Reinsert the charge connector and Restart
160186-Staff-POD-9-30