BTCPower EVPC-150-2-480-3-65 User manual

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

150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 2of 63
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 D
PLEASE NOTE
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.
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 should be operated by trained personnel only.
MANUFACTURER:
www.btcpower.com
OFFICE ADDRESS:
1719 S. Grand Ave., Santa Ana, CA 92705
CONTACT INFORMATION:
Phone: [phone]
Fax: [phone]
Email: [email protected]

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 D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 3of 63
TABLE OF CONTENTS
Table of Contents
1. Safety Guidelines ..................................................................................................................................... 5
1.1. Important Safety Instructions .................................................................................................................. 5
1.2. Symbols and Definitions .......................................................................................................................... 6
2. System Overview ..................................................................................................................................... 7
3. Equipment Description ............................................................................................................................ 8
4. System Specification ............................................................................................................................. 11
4.1. DCFC Power Box .................................................................................................................................... 11
4.2. DCFC Dispenser...................................................................................................................................... 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
6.1. Packaging .............................................................................................................................................. 18
6.2. Transport, Handling, and Storage ........................................................................................................ 18
6.3. Receiving and Unpacking .................................................................................................................... 19
7. Installation............................................................................................................................................... 20
7.1. Moving and Hoisting Instructions ......................................................................................................... 21
7.2. Mounting Procedures ............................................................................................................................ 24
7.2.1. Clearance Around the Unit .................................................................................................................. 24
7.2.2. Tower and Dispenser Mounting............................................................................................................ 25
7.3. Electrical and Communication Service Connection ........................................................................ 28
8. Verification and Inspection .................................................................................................................. 36
9. Operation................................................................................................................................................ 37
9.1. System Power Up.................................................................................................................................... 37
9.2. Output Connectors................................................................................................................................ 38
9.2.1. CHAdeMO Connector (200 A)............................................................................................................. 38
9.2.2. 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.
10-Dec-20
Revision D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 4of 63
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 Cooled Coupler (500A Rated) .................................................................. 54
b) Cooling Unit System ............................................................................................................................... 55
c) Cool Cable Coolant .............................................................................................................................. 56
d) SAE J1772 CCS1 Coupler (200A Rated) .............................................................................................. 58
e) CHAdeMO High Power Coupler (200A Rated) .................................................................................. 58
12.2. Cooling Unit System Overview ............................................................................................................. 59
a) Main Parts ............................................................................................................................................... 59
b) 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.
10-Dec-20
Revision D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 5of 63
SAFETY GUIDELINES
1. Safety Guidelines
SAVE THESE INSTRUCTIONS
This document contains important instructions for the installation, operation, and maintenance
of 150kW High Power DC Charger. These instructions should be retained for future reference.
1.1. Important Safety Instructions
DANGER
READ THIS MANUAL BEFORE YOU BEGIN
This 150kW High Power DC Charger manages electricity and may be hazardous. The
equipment should be installed, adjusted, and serviced only by qualified electrical personnel
familiar with the construction and operation of this type of equipment and the hazards
involved, and in full compliance with all local and national codes and standards. 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 manual and energizing the equipment. Inspection and
maintenance of this equipment should be performed in accordance with the procedures
detailed in this manual.
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.
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. SERVICE TO THE
UNIT SHALL ONLY BE PERFORMED BY A QUALIFIED PERSONNEL.
If the charging cable is somehow damaged, do not operate the charge station. Contact your
service representative for service immediately. Shut down the power to the tower by switching
the breaker on the supply panel to the off position.

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 D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 6of 63
SAFETY GUIDELINES
1.2. Symbols and Definitions
Please take special attention to all information marked with the following symbols. These
symbols may be found throughout the 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 the instructions carefully. Failure
to do so will result in severe injury or possibly death.
WARNING
Indicates a hazard or unsafe practice which, if not avoided,
may result in severe injury or possibly death.
CAUTION
Indicates a hazard or unsafe practice which, if not avoided,
may result in minor to moderate injury.
NOTE
Indicates important information to consider, otherwise,
improper installation and/or damage to components may
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.
10-Dec-20
Revision D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 7of 63
SYSTEM OVERVIEW
2. System Overview
The 150kW High Power DC Charger converts a 480VAC 3-phase 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 System (CCS)
standards.
The charger is composed of a 150kW Power Box (with 3 individual 50kW power modules on it)
and one or two dispenser/s depending on the configuration. The dispensers can either be a
Dual CCS or CCS/CHAdeMO configuration and a 350A or 200A rated.
➢SIMPLIFIED BLOCK DIAGRAM (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.
10-Dec-20
Revision D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 8of 63
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. Output Contactors (+/-) Power Module #2
6. Output Contactors (+/-) Power Module #1
7. Air Vent
8. Master Controller
9. Safety Relays
10. 24VDC Power Supplies
11. 12VDC Power Supply
12. Input Section
13. Output Section
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.
10-Dec-20
Revision D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 9of 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 Security Lock
5. Charging Connector 1
6. Charging Connector 2
7. Customer Advertising Panel
8. Start Button / Function Key 1
9. Stop Button / Function Key 2
10. Emergency Stop Button / Function Key 3
11. Air Inlet (left side)
12. Air Exit (right side)

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 D
150kW High Power DC Charger
INSTALLATION AND USER’S MANUAL
Page 10 of 63
EQUIPMENT DESCRIPTION
SYSTEM 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 Dispenser, CCS/CHAdeMO
EVDSP-350-5-120-0-2-C-4-0
HPCD1-350-01-003
3
DCFC 350A Dispenser, Dual CCS
EVDSP-350-4-120-0-2-C-4-0
HPCD1-350-02-003
4
DCFC 200A Dispenser, CCS/CHAdeMO
EVDSP-200-5-120-0-2-C-4-0
HPCD1-200-01-003
5
DCFC 200A Dispenser, Dual CCS
EVDSP-200-4-120-0-2-C-4-0
HPCD1-200-02-003