EVBOLT POWERHAUL 3 User manual

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Electric Vehicle DC Charger
POWERHAUL 3 – User Manual
EVB-DC-PM30
POWERHAUL
3

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Contents
1. Introduction..................................................................................................................................................................... 1
2. Features........................................................................................................................................................................... 1
3. Applications.................................................................................................................................................................... 1
4. User Interface.................................................................................................................................................................. 2
5. Specifications.................................................................................................................................................................. 4
5.1 Product Specification.............................................................................................................................................. 4
5.2 LED Indication and Operation Status..................................................................................................................... 6
5.3 Dimensions ............................................................................................................................................................. 7
5.4 Direction of cooling Airflow................................................................................................................................... 7
6. Installation Instructions................................................................................................................................................... 8
6.1 Before Installation................................................................................................................................................... 8
6.2 Grounding and Safety Requirement........................................................................................................................ 9
6.2.1 Service Wiring .............................................................................................................................................. 10
6.3 Unpack the charger ............................................................................................................................................... 11
6.4 Recommended Tools for Installation and Inspection............................................................................................ 14
6.4.1 Recommended Tools for Installation............................................................................................................ 14
6.4.2 Recommended Tools for Inspection & Commissioning............................................................................... 14
6.5 Installation Procedure ........................................................................................................................................... 15
6.6 Installation Inspection & Commissioning............................................................................................................. 17
6.6.1 Environmental Check.................................................................................................................................... 17
6.6.2 External Infrastructure Readiness & Check.................................................................................................. 17
6.6.3 EVSE Check – Static (Non-Powered)........................................................................................................... 18
6.6.4 EVSE Check – Powered On.......................................................................................................................... 18
6.6.5 EVSE Check – Charging............................................................................................................................... 19
6.6.6 EVSE Check – Emergency stop check ......................................................................................................... 19
7. Operation Process ......................................................................................................................................................... 20
7.1 Operating Sequence .............................................................................................................................................. 20
7.2 Operating Procedure (ONLINE)........................................................................................................................... 20
7.2.1 EVBOLT iOS/Android Application ............................................................................................................. 20
7.2.2 EVBOLT WebApp ....................................................................................................................................... 20
7.3 Operating Procedure (OFFLINE) ......................................................................................................................... 21
7.3.1 System Initialization ..................................................................................................................................... 21
7.3.2 User Authorization........................................................................................................................................ 22
7.3.3 Plug in Charging Connector.......................................................................................................................... 23

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7.3.4 Prepare for Charging..................................................................................................................................... 23
7.3.5 In Charging ................................................................................................................................................... 24
7.3.6 Charging Terminated .................................................................................................................................... 25
7.3.7 Status Message.............................................................................................................................................. 25
7.4 Troubleshooting.................................................................................................................................................... 26
7.5 Status Codes.......................................................................................................................................................... 26
8. Maintenance.................................................................................................................................................................. 47
8.1 General Maintenance ............................................................................................................................................ 47
8.2 Replacement Kits and Accessories....................................................................................................................... 49
9. Limited Product Warranty ............................................................................................................................................ 50
10. Packing List .............................................................................................................................................................. 51

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1. Introduction
The Movable DC Fast Charger is the top choice to power battery electric vehicles (BEV) and plug-in electric
vehicles (PHEV). It is designed for quick charging in both public and private locations, such as retail and
commercial parking spaces, fleet charging stations, highway service areas, workplace, residence, etc.
The Movable DC Fast Charger has the advantage of mobility, it is freely to access EV and charging. The Movable
DC charger also has network communication capability. It is able to connect with remote network systems and
provide drivers of electric cars real-time information, such as the location of charging stations, charging progress
and billing information. The Movable DC Fast Charger has a clear user interface with function buttons, safety
certifications and an excellent waterproof and dust proof design to provide the best choice for outdoor
environments.
2. Features
• Movable design and pluggable power modules make installation easy and flexible.
• Offers customers the convenience of start/stop charging control from an authorized RFID smart card or
mobile APP.
• Built on latest industry standards for DC charging.
• Carries an outdoor rating capable of withstanding solid and liquid intrusions in outdoor settings making the
unit more stable and highly reliable.
• Provides a high-contrast, screen interface with multi-function buttons.
3. Applications
• Parking garage
• Commercial fleet operators
• EV dealer workshops
• Auto service center

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4.User Interface
Cable holder
Antenna
Emergency Stop
USB Port
RJ45 Port
Door handle
CEE Socket 5pin 3P+N+PE Male
480Vac, 50A
Handle
Charger Gun Cable Holster
Leveling caster x 4pcs
Adjust the leveling feet to fix the charger
7" Information Screen
Right Button Left
Button RFID Card
Reader
•Charging Status
•Alarm information
•User Authorization
Indication Light
Indication Light

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Charger Gun Holster
Charger Gun Storage

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5. Specifications
5.1 Product Specification
Model ASTEROPE 3 (EVB-DC-PS30)
AC
INPUT Voltage Rating 3Φ480Vac (+10%, -15%)
Input Current 40A
Electrical Distribution 3P+ N+ PE (Wye configuration)
Power Grid System TN/TT
Frequency 50/60Hz
Max. Input Power 33kVA
Power Factor > 0.99
Efficiency > 94%, at optimize V/I point
DC
OUTPUT Output Voltage Range CCS1:150Vdc ~ 950Vdc
Maximum Output Current CCS1: 60A@150Vdc ~ 500Vdc when output
voltage up to 950Vdc the output current is 31.5A
Maximum Output Power DC 30kW
Voltage Accuracy ±2%
Current Accuracy ±2%
Communication External Ethernet, Wi-Fi and 3G or 4G
Internal CAN Bus / RS485
Input Protection OVP, OCP, OPP, OTP, UVP, SPD
Output Protection SCP, OCP, OVP, LVP, OTP, IMD
Internal Protection OTP, AC Contactor Detection, DC Contactor Detection, Fuse Detection
Electrical Isolation Isolation between Input and Output
Standby Power < 100W
User Interface & Control Display 7-inch LCD
Button Left Button: Home / Stop charge
User Authentication RFID Support ISO 14443A/B, ISO 15693, FeliCa
Lite-S (RCS966), OCPP, 2D Barcode, APP,
Mobile Payment
Backend Support OCPP 1.6 JSON
Display information *Charging process and status
*Status codes

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Environmental
Conditions Operation Temperature -22°F to 122°F (-30°C to 50°C), power derating
from 122°F (50°C) and above
Storage Temperature -40°F to 158°F (-40°C to 70°C)
Relative Humidity 5%~95% RH, non-condensing
Altitude ≤ 6560 ft (2000m)
Regulations
Safety UL2202, UL2231
EMI/EMC FCC CFR Title 47 Part15
Subpart B: 2020
ANSI C63.4:2014
ICES-003:2020 Issue 7
Charging Interface CCS DIN 70121
Mechanical
Specifications Input cable and connection 10m cable with CEE socket
Dimensions (WxDxH mm) 23 x 24 x 39 inches (589 x 620 x 988 mm)
Weight (typ.)
≦
176 lbs. (80kg)
DC Charging Connector CCS1 or CHAdeMO or GB/T
Charging Cable Length < 16ft (5m)
Charging Cable Number One
Input cable and connection 63A Socket & 10M,16mm2 AC Cable
Cooling Fan cooling
Ingression Protection NEMA 3R
Anti-vandalism IK10, does not include LCD & RFID cover
Acoustic Noise (dB(A))
≦
65dB(A) (Pout with DC 25kW at Rt=30°C)

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5.2 LED Indication and Operation Status
LED Status Light Remark
Standby Green
Fault Red
Charging Blue

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5.3 Dimensions
Charger
Unit: mm
5.4 Direction of cooling Airflow
589 155
740
92 Ref
160
490 130
Air Out Air In

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6.Installation Instructions
6.1 Before Installation
•Read all the instructions before using and installing this product.
•Do not use this product if power cable or charging cable have any damage.
•Do not use this product if the enclosure or charging connector are broken or open or if there is damage.
•Do not put any tool, material, finger or other body part into the charging connector or EV connector.
•Do not twist, swing, bend, drop or crush the charging cable. Never drive over it with a vehicle.
Warning: The product should be installed only by a licensed contractor and/or licensed technician in
accordance with all building codes, electrical codes and safety standards.
Warning: The product should be inspected by a qualified installer prior to initial use. Under no
circumstances will compliance with the information in this manual relieve user of his /her
responsibilities to comply with all applicable codes and safety standards.
•Power feed must be 3 Phase Wye configuration with TN(-S)/TT grounding systems.
•In the installation of TN(-S) system: the neutral (N) and the PE of the power distribution are directly
connected to the earth. The PE of the charger equipment is directly connected to the PE of power distribution
and separate conductor for PE and neutral (N).
•In the installation of TT system: the neutral (N) and the PE of the power distribution are directly connected
to the earth. The PE of the charger equipment is isolated to the PE of power distribution to the earth.
•The capacity of power supply should be higher than 33.0kVA in order to function correctly.
•The product should be installed in free air area and keep at least 30cm clearance distance to all air vent of
the product.
•Need sufficient space for product installation and maintenance, please keep not less than 60cm clearance
distance from all around the product.
•Do not move the charge in speed higher then 1Meter/second (about 3.6Km/h normal walking speed), and do
not move at bumpy surface.

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NOTICE
It is recommended to conduct Wi-Fi and 4G signal strength while charger installation. The
RSSI (Received Signal Strength Indication) value is considered as good as higher than -65
dBm. Poor connection quality might interrupt charging process or data transaction.
6.2 Grounding and Safety Requirement
• The product must be connected to a grounded, metal, permanent wiring system. Connections shall comply
with all applicable electrical codes.
• Ensure no power is connected at all times when installing, servicing, or maintaining the charger.
• Use appropriate protection when connecting to main power distribution network.
• Use appropriate tools for each task.
• Do not apply electrical power to charger or charging cars before the charger is well parked.
CAUTION: The disconnect switch for each ungrounded conductor of AC input shall be provided by
installation contractor or technician in accordance with the National Electric Code, ANSI/NFPA 70.
CAUTION: A cord extension set or second cable assembly shall not be used in addition to the cable
assembly for connection of the EV to the EVSE.

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6.2.1 Service Wiring
Ground Connection
Always connect the Neutral at the service to Earth Ground. If ground is not provided by the electrical service,
then a grounding stake must be installed nearby. The grounding stake must be connected to the ground bar in the
main breaker panel and Neutral connected to Ground at that point.
480Vac (Line to Line) Three-Phase
CAUTION!
This is feed from Wye-connection power grid, the Standalone DC Fast Charger can connect to L1,
L2 or L3, and Neutral. Earth ground must be connected to neutral at only one point, usually at the
breaker panel.
DANGERS
Be Aware of High Voltage!
WARNING!
Earth Connection is Essential!
480V Three-Phase Wiring Connection
PE
277V 277V
277V
Neutral 480V
L3
L1
L2

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6.3 Unpack the charger
1. The product is Direct current (DC) charger, the packing design passed the packaging simulation test, if
the packaging is damaged cause by overturning, falling or external impact during transportation, it may
cause the product damage or defects. if there is any serious damage to the packaging when receiving the
goods, please notify manufacturer (Supplier) about your findings.
2. Receiving the DC 30KW Moveable. The product is delivered by a transport company to a warehouse or
specified location where it will be handed over. Transporting the DC 30KW Moveable to its final location
(last mile service) is not standard included in the order.
3. NOTICE: The delivery truck unloads the pallet carrying the DC 30KW Moveable. The movement of the
30KW Moveable to its final location is the responsibility of the customer / contractor.
Checking the TiltWatch sensors: If the TiltWatch indicator is tilted over 80°
1. Do not refuse the delivery / receipt.
2. Make a notation on the delivery receipt and inspect cabinet for damage.
3. If damage is discovered, leave cabinet in original package and request immediate inspection from carrier
within 3 days of delivery.
4. Contact Supplier technology to notify us about your findings.
WARNING!
Charger weight might be 176 lbs. (80 kg).
Be careful during unpack process.

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STEP 1
Remove the surrounding boards.
STEP 2
Remove the packaging film and the paper cover. Accessories (wall mount) are packed in a carton.

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STEP 3
Remove the surrounding cardboard and film. Take out the Charger and Gun holders.

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6.4 Recommended Tools for Installation and Inspection
6.4.1 Recommended Tools for Installation
Type Description
Philips Screwdriver No. 2 and 3
Shifting Wrench 8” (24mm)
Ball-Head Hex Key 2.5mm and 5mm
Socket Screwdriver No. 8 and 10
Electrical Tape Black / 15mm (0.6”) Width
AC Input Cable AWG#5 (16mm2) Cable x 5 (L1, L2, L3, N, PE)
Ring Terminal AWG#5 x 5 (L1, L2, L3, N, PE)
Ring Terminal (inside diameter is 6.4mm; outer diameter is 15.1mm)
Crimping Pliers for Ring Terminal
Wire Stripper & Cutters
6.4.2 Recommended Tools for Inspection & Commissioning
Type Description
EV or EV Simulator Meet CHAdeMO/CCS Standard
Multiple Meter 1000V
Current Probe 100Amp
RFID Authorized Card
RFID No Valid Card
Door Key
Needle-Nose plier
Wi-Fi /4G signal quality checker Recommended

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6.5 Installation Procedure
STEP 1
Place the movable charger on the flat ground, push down all front wheel-brakes until hearing the click sound.
STEP 2
Open the side door and fasten the female CEE plug on the extension cable into the male CEE socket on charger,
make sure both sides are inter-locked appropriately then close the door.
*Caster type may variant which
subject to local regulation

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STEP 3
Fasten AC power cord to the wall socket or distribution box according to local regulation and shall be operated
by qualified technician. *The setting is different from each local. First depend on the qualified technician check
the power cord type and setting.
General cord color: [L1]-Brown/ [L2]-Orange/ [L3]-Yellow/ [N]-Grey/ [G]-Green-Yellow
STEP 4
Turn on the power source and then operation screen will be ready within 30 seconds.
L1 L2 L3 N

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6.6 Installation Inspection & Commissioning
6.6.1 Environmental Check
Item Status Remark
Ambient Temperature
Ambient Humidity
Sunshade Recommended but not required.
Rain Canopy Recommended but not required.
Air Circulation / Drafty
Dust Level
Anti-Vandalism Measures
6.6.2 External Infrastructure Readiness & Check
Item Status Remark
Input Wirings & Terminals
Key & Lock of Cabinet Door
Input Electricity Capacity
Input Electricity Configuration Wye
Grounding Resistance < 10 Ω
Grounding System TN
Input Voltage & Frequency
Network Connection & Quality Wi-Fi, 4G > -65dBm