BTCPower L3R-50-208-01-003 User manual

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

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 2of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
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.

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 3of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
Table of Contents
1. Safety Guidelines ......................................................................................................................4
1.1. Important Safety Instructions....................................................................................................4
1.2. Symbols and Definitions ............................................................................................................5
2. System Overview.......................................................................................................................6
2.1. Equipment Description .............................................................................................................6
2.2. Equipment Specification ..........................................................................................................7
3. Pre-Installation...........................................................................................................................8
3.1. Location Selection ....................................................................................................................8
3.2. ADA Consideration ...................................................................................................................9
4. Installation................................................................................................................................11
4.1. Mounting Procedures .............................................................................................................12
4.1.1.Clearance Around the Unit....................................................................................................12
4.1.2.Charger Mounting ..................................................................................................................13
4.2. Electrical and Communication Service Connection...........................................................15
4.2.1.Electrical Service Entrance.....................................................................................................15
4.2.2.Electrical Connection .............................................................................................................16
5. Operation.................................................................................................................................18
5.1. Charging Session and Operating Procedure .......................................................................18
5.2. Stop Procedure .......................................................................................................................21
5.3. Time Outs .................................................................................................................................22
6. Maintenance ...........................................................................................................................23
7. Warranty...................................................................................................................................24
TABLE OF CONTENTS

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 4of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
1. Safety Guidelines
SAVE THESE INSTRUCTIONS
This document contains important instructions for the installation, operation, and maintenance
of 50kW DC Fast Charger. These instructions should be retained for future reference.
1.1. Important Safety Instructions
WARNING
READ THIS MANUAL BEFORE YOU BEGIN
This 50kW DC Fast 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 specified
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 specified 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 your charging cable is somehow damaged, do not operate the charge station. Contact your
service representative for service immediately. Shut down the power to the charger by
switching the breaker on the supply panel to the off position.
SAFETY GUIDELINES

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 5of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
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.
SAFETY GUIDELINES

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 6of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
2. System Overview
The 50kW DC Fast Charger converts a 208VAC or 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.
2.1. Equipment Description
50 kW DC FAST CHARGER
DESCRIPTION
1. Charge Cord Retractor
2. 15" Outdoor-Rated Touch Screen Display
3. RFID Card Reader
4. Emergency Stop Button
5. High Security Lock
6. Charging Coupler (for dual port)
-CHAdeMO, SAE Combo
7. Air Vent
8. LED Light
9. Encrypted Insert Card Reader
10. Stop Button
11. Start Button
12. Charging Coupler
-CHAdeMO, SAE Combo
SYSTEM OVERVIEW

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 7of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
2.2. Equipment Specification
PARAMATER
MODEL
L3R-50-208-01-003
L3R-50-208-05-003
L3R-50-208-06-003
L3R-50-480-01-003
L3R-50-480-05-003
L3R-50-480-06-003
Power Rating
50 kW
50 kW
Connectors
CHAdeMO, SAE J1772 Combo CCS1
Network Compatibility
OCPP 1.5/1.6, BTCP Network
Access Control –
Communication
RFID, Credit Card –4G, Cat-5 Ethernet
Input Power
208 VAC 3-Phase
480 VAC 3-Phase
Full Load Amperage
177 A
72 A
Efficiency Rating
> 90%
Max. Output DC Current
125 A
Max. Output DC Voltage
50 - 500 V
Plug-Out Detection
Power Terminated per SAEJ1772 or GB/T Specifications
Surge Protections
6000 VAC
Ambient Condition
-30°C to +50°C, 95% Humidity Non-Condensing, 6000 ft Altitude
Dimension & Weight
43" W x 73" H x 33" D, 1000 lbs
Safety Compliance
ETL Listed for USA and Canada: Complies with UL 2202, UL 2231,
UL 50E, NEC Article 625, CSA Std C22.2 No. 107.1, FCC Part 15 Class A
SYSTEM OVERVIEW

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 8of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
3. Pre-Installation
Prior performing any installation activities, it is important to go through each of the items
outlined in this section which are essential for the installation process.
3.1. Location Selection
Thing to consider when choosing a location to install the unit:
•Standards for Accessible Design (refer to Section 3.2)
•Conformance to all governing standards for location and placement of the charger
•Communications Connectivity
oRefer to BTCPower guidelines in “Determining Suitability of Site for Cellular Connectivity”
oEnsure that installation location meets the Cellular Signal Strength Criteria below
Parameter
Min Value
Device
Notes
RSSI
-69 dBm
SureCall
If RSSI < - 69dBm, measure RSRP,
RSRQ, and SNIR
RSRP
-100 dBm
Squid or BTC-Cellular Meter
Please consult BTCPower
Application Engineering
RSRQ
-11 dBm
Squid or BTC-Cellular Meter
Please consult BTCPower
Application Engineering
SNIR
> 6 dB
Squid or BTC-Cellular Meter
For Reference
•Local Conditions
oArea is not expose to high temperatures, dust, corrosive fumes, combustible materials, or
explosive gases
oArea is dry and well-ventilated
oClearances at front, back, and sides for accessibility during service (refer to Section 4.1)
oWiring and conduit needed to connect the charger to the circuit panel
oLocation of vehicle’s charging inlets while parked
oUse of protective bollards and wheel stops to protect the charger
PRE-INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 9of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
3.2. ADA Consideration
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
PRE-INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 10 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
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).”
Compliance to ADA Standards
Access to all the controls and commands including the buttons and the card reader, must
comply with local codes and ADA requirements. That includes being under 48” of distance to
the ground.
PRE-INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 11 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
4. Installation
SAFETY INSTRUCTIONS
The 50kW DC Fast Charger should be installed in accordance with local codes and all
applicable ordinances.
Read all installations instructions carefully prior to performing the installation.
DANGER
The equipment utilizes high voltages, only qualified electrical personnel familiar with the
operation and construction should install, adjust, modify, and service this equipment. Failure to
observe this precaution could result to severe injury or death.
WARNING
•The equipment may be installed outdoors but only use under environment conditions as
stated in this document.
•Do not perform any live wire operations.
•Do not touch the inside of the equipment while it is running.
•This equipment includes capacitive components such as electrolytic capacitors. Some parts
may still remain charged inside of the unit even after the input power is disconnected.
•This charger should not be modified in any way. This will void the warranty, compromise
protection and could result in a possible shock or fire hazard.
•Personal Protective Equipment should be used at all times when working with the equipment.
CAUTION
During installation of the unit, ensure that the charge station’s supply cable is in such a way that
it will not be tripped over, stepped on, pulled on, or somehow subjected to damage or stress.
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 12 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
4.1. Mounting Procedures
4.1.1. Clearance Around the Unit
Clearance surrounding the charger must be considered for proper ventilation and service
accessibility. Refer to the installation drawings as illustrated below.
Charger Installation Drawing
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 13 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
Charger Installation Drawing (continuation)
4.1.2. Charger Mounting
The Charger must be fixed on a concrete pad using four (4) ½" x 3 ¾" (McMaster-Carr P/N
91578A116 or equivalent) concrete expansion studs or as determined appropriate by the
structural engineer in-charge.
Make sure to check local codes for compliance.
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 14 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
Charger Footer Drawing
The illustration below shows the drilling layout for the Charger. Only four (4) points are needed to
fix the unit on the concrete pad. The conduit entry to the unit is also shown.
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 15 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
4.2. Electrical and Communication Service Connection
4.2.1. Electrical Service Entrance
50kW DC Fast Charger is provisioned to receive an electrical power connection from the
bottom. Refer to all applicable codes.
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 16 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
4.2.2. Electrical Connection
CAUTION
This is a 3-Phase 208VAC or 480VAC EVSE Charger.
The 50kW DC 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 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 standards.
50KW Charger 480VAC 3-Phase Input
50KW Charger 208VAC 3-Phase Input
3 AWG Line for each phase
3/0 AWG Line for each phase
3 AWG GROUND wire
3/0 AWG GROUND wire
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 lug or lead on battery charger. Connections to the charger shall comply with all
local codes and ordinances.
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 at its installation location.
*Line 1, Line 2, Line 3, and Ground wires are required, neutral is not required.
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 17 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
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 of the Breaker
Panel.
Electrical Connection
Connect 3-Phase (208VAC or 480VAC) to the Mersen Terminal Block MPDB67013 in the lower
compartment of the 50kW DC Fast Charger.
MERSEN TERMINAL BLOCK (MPDB67013)
Line Side
Load Side
Amp Rating per Pole
Wire
Range
Opening
per Pole
Torque
(lb-in)
Wire
Range
Opening
per Pole
Torque
(lb-in)
Cu Wire
Al Wire
350 –6
1
275
2/0 –6
2
120
310 A
250 A
8 –14
2
50
INSTALLATION

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 18 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
5. Operation
5.1. Charging Session and Operating Procedure
SCREEN
DESCRIPTION
SCREEN 1
WELCOME SCREEN
Displays Connector Options
Select:
CCS Combo
CHAdeMO
SCREEN 2
Displays Pricing Details
SCREEN 3 –Credit Card Option
Swipe Credit Card to Proceed
SCREEN 3 –RFID Card Option
Hold RFID Card Close
to the Reader to Proceed
OPERATION
Touch for
CCS Combo
Touch for
CHAdeMO

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 19 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
SCREEN
DESCRIPTION
SCREEN 4
Charging Receipt Text Message
Option
Enter Phone Number and Press
“Submit” or Press “Skip”
SCREEN 5
Authorizing Payment
SCREEN 6
Connect Vehicle
to begin
Charging Initialization
SCREEN 7
Charging in Progress
and Displays Charging Information
Press “STOP”
to Discontinue Charging
OPERATION
Press STOP to
stop charging

50 kW DC Fast Charger
INSTALLATION AND USER’S MANUAL
Page 20 of 26
This document is the Property of BTCPower Inc. and shall not be
copied, reproduced, or used as the basis for sale or manufacture
of apparatus without written permission.
29-May-19
Initial Release
SCREEN
DESCRIPTION
SCREEN 8
Charging Stopped / Completed
Wait for Instruction
SCREEN 9
End of Charging
Unplug Connector
and Return to Holder
OPERATION