FREEWIRE Boost Charger Operating instructions

Boost Charger™
DC Fast Charging Station
Operating and
Maintenance Manual
Version 1.0

Copyright and trademarks
©2014-2020 FreeWire Technologies, Inc. All rights reserved. This material is protected by the copyright
laws of the United States and other countries. It may not be modified, reproduced or distributed without the
prior, express written consent of FreeWire Technologies, Inc. FREEWIRE, FREEWIRE TECHNOLOGIES, AMP
and BOOST CHARGER are U.S. registered trademarks and service marks of FreeWire Technologies, Inc. and
cannot be used without the prior written consent of FreeWire®. No part of this document may be photocopied,
reproduced or translated to other language without the express written consent of FreeWire®.
No accuracy guarantee
FreeWire® has taken commercially reasonable efforts to ensure the accuracy, reliability and completeness of
the specifications and other information in this manual at the time of its publication. However, the information is
provided “as is” without warranty of any kind, and the specifications and other information in this manual do not
constitute a contractual obligation and are subject to change at any time without prior notice. FreeWire does
not accept any responsibility or liability regarding the accuracy, content, completeness, legality or reliability of
the information contained herein.
Product disclaimer
The Boost Charger™ is designed for specific applications and should not be used for any purpose not
expressly set forth in applicable FreeWire product documentation.
Warranty information and disclaimer
The Limited Warranty you received with your Boost Charger™ is subject to certain exceptions and exclusions.
For example, your use of, or modification to, the FreeWire® Boost Charger™ in a manner in which it is not
intended to be used or modified will void the limited warranty. You should review your warranty and become
familiar with the terms thereof. Other than any such limited warranty, the FreeWire® products are provided “AS
IS,” and FreeWire Technologies, Inc. and its distributors expressly disclaim all implied warranties, including any
warranty of design, merchantability, fitness for a particular purposes and non- infringement, to the maximum
extent permitted by law.
Limitation of liability
IN NO EVENT SHALL FREEWIRE BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, INCIDENTAL, SPECIAL
CONSEQUENTIAL DAMAGES, TO PROPERTY OR LIFE, WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST
PROFITS, LOST BUSINESS, LOST DATA, LOSS OF USE OR COST OF COVER INCURRED ARISING OUT OF OR
CONNECTED WITH THE USE, MISUSE OR INABILITY TO USE THE BOOST CHARGER, UNDER ANY THEORY
OF LIABILITY, WHETHER IN AN ACTION IN CONTRACT, STRICT LIABILITY, TORT (INCLUDING NEGLIGENCE)
OR OTHER LEGAL OR EQUITABLE THEORY, EVEN IF FREEWIRE KNEW OR SHOULD HAVE KNOWN OF THE
POSSIBILITY OF SUCH DAMAGES. IN ANY EVENT, THE CUMULATIVE LIABILITY OF FREEWIRE FOR ALL
CLAIMS WHATSOEVER RELATED TO THE BOOST CHARGER SHALL NOT EXCEED THE PRICE YOU PAID FOR
THE BOOST CHARGER. THE LIMITATIONS SET FORTH HEREIN ARE INTENDED TO LIMIT THE LIABILITY OF
FREEWIRE AND SHALL APPLY NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED
REMEDY.

DRAFT
Safety and compliance
The FreeWire Boost Charger is for Outdoor Use Only and to be mounted on a non-combustible surface such as
a concrete pad that extends a minimum of 3 feet beyond the perimeter of the battery system/Boost Charger.
The Boost Charger should comply with all local and national codes and standards and only be installed by a
licensed contractor and a licensed electrician.
It is the site owner’s responsibility to comply with all local codes and safety laws. The most common installation
method is discussed in this guide. If for any reason it is not possible to perform the installation following the
guide, contact FreeWire Technologies, Inc. FreeWire Technologies, Inc. is not responsible for any damages that
may occur resulting from deviations from the instructions outlined in this guide.
Lithium-Ion Battery
FreeWire Battery Pack 820-00114-01 is to be used exclusively with the Boost Charger.
FCC Compliance Statement
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the manufacturer’s instruction manual,
may cause harmful interference with radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference, in which case, you will be required to correct the interference at your own
expense.
Important: Changes or modifications to this product not authorized by FreeWire Technologies, Inc., could affect
the EMC compliance and revoke your authority to operate this product.
Exposure to Radio Frequency Energy: The radiated power output of the 802.11 b/g/n radio and cellular modem
in this device is below the FCC radio frequency exposure limits for uncontrolled equipment. The antenna of this
product, used under normal conditions, is at least 20 cm away from the body of the user. This device must not
be co-located or operated with any other antenna or transmitter by the manufacturer, subject to the conditions
of the FCC Grant.

This page is left intentionally blank

DRAFT
Boost Charger
DC Fast Charging Station
Operating and Maintenance Manual
Version 1.0
Table of Contents
1 INTRODUCTION................................................................................................................................... 6
1.1 Overview............................................................................................................................................................ 6
2 OPERATING THE BOOST CHARGER............................................................................................... 7
2.1 Powering on the Boost Charger................................................................................................................. 7
2.2 Shutting Down the Boost Charger ............................................................................................................ 7
2.4 Configure System Behavior......................................................................................................................... 8
2.5 Charging an EV................................................................................................................................................. 8
2.6 LED Status Indicators.................................................................................................................................... 9
3 USER INTERFACE WALK-THROUGH............................................................................................... 10
3.1 Getting Started ................................................................................................................................................ 10
3.2 Payment ............................................................................................................................................................. 11
3.3 CONNECT TO THE EV .................................................................................................................................... 11
3.4 Active Charging ............................................................................................................................................... 12
3.5 DUAL CHARGING............................................................................................................................................. 13
3.6 STOP CHARGING............................................................................................................................................. 13
3.7 Driver Support ................................................................................................................................................. 14
4 BOOST CHARGER MAINTENANCE................................................................................................. 15
4.1 Maintenance Overview.................................................................................................................................. 15
4.2 Site Operator’s Responsibilities................................................................................................................. 15
4.3 Preventative Maintenance ........................................................................................................................... 15
5 BOOST CHARGER SPECIFICATIONS ............................................................................................. 17

6
1INTRODUCTION
1 Introduction
This manual describes how to operate and maintain the FreeWire Boost Charger DC fast charging station
and is intended for use by a station owner or facility manager.
1.1 Overview
Boost Charger is equipped with a 24-inch ruggedized touch screen that meets ADA accessibility
requirements. A credit card terminal with NFC and RFID capabilities, as well as an emergency stop button, are
located prominently below the screen.
Display
Safety Shutdown
Button
Status
Indicators
CHAdeMO/CCS
Plug & Cable
Wireless
Antenna
Area Light
RFID Card Reader with
Payment Terminal

7
2OPERATING THE BOOST CHARGER
2 Operating the Boost Charger
2.1 Powering on the Boost Charger
There is an emergency stop button, however there is no separate on/off switch for the Boost Charger.
Note: The emergency stop button should not be used as an on/off switch.
The Boost Charger fast charging station is powered on during the installation by energizing the site’s
electrical panel. Immediately after completing installation and the electrical breaker is turned on, the system
will turn on and run a series of self-tests to ensure safe operation.
These tests include:
• Electrical component safety checks
• Lighting and display checks
• Battery charging system checks
• Component operation checks (such as fans, pumps, and contactors)
• Cellular connectivity checks
If any errors are found, the display will report that the charger is not available for use and the indicator lights
will turn red. Contact EV Connect at [phone] for assistance.
2.2 Shutting Down the Boost Charger
The Boost Charger only needs to be powered off during service by using the electrical breaker at the main
panel. Otherwise, there is no separate power switch. No components will be damaged when the power is
shut off, as the system is designed to be shut off by the breaker. Also, there is no need for any software
commands to turn off the station.
The Boost Charger has the ability to be turned off by use of a remote shut off switch. See the Boost Charger
Installation Guide for more details. Whether this feature is used and where the switch is located varies by site.
IMPORTANT: Only qualified technicians or FreeWire approved personnel are able to complete the
installation of, or perform service on a Boost Charger. For more information please visit
www.freewiretech.com
DANGER: RISK OF ELECTRIC SHOCK.
Before beginning any work on the Boost Charger, the power must be disconnected at the service
panel. Standard practice must be followed as well as local codes to de-energize the circuit.
Standard lock out/tag out procedures should also be followed. It is recommended to use a
multimeter to test that the power is off before service. The power should remain off for the Boost
Charger until all service doors and panels are properly reinstalled and the work is completed.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.

8
2OPERATING THE BOOST CHARGER
2.4 Configure System Behavior
The site manager and/or station operator has the ability to customize a number of the Boost Charger
software features. These include:
• Setting pricing for electric vehicle (EV) drivers
• Set different pricing/access policies for different groups
To configure or make changes to settings at any time, log in to your EV Connect Administrator Portal by
visiting https://ops.evconnect.com/admin/login
For assistance with the Administrator Portal, please contact the EV Connect Site Host Support line by calling
[phone].
2.4.1 User Interface Branding
The Boost Charger user interface (UI) has space available for custom branding, promotions, etc. Contact
FreeWire at [e-mail] for more information.
2.5 Charging an EV
Pay, Plug, Go.
Step 1 Park vehicle as close as possible to available charge port. Connector type and location of charge
port varies by vehicle model. Refer to individual vehicle owner’s manual for specifications.
Step 2 Open vehicle charge port.
Step 3 Use the Boost Charger’s touchscreen to start charging. Select the plug on the screen that
corresponds to the port you wish to use. For an in-depth walk-through of the user interface, see
section 3.
Step 4 Complete payment prompts.
Step 5 Press the button on the selected connector handle to release cable from the holster.
Step 6 Plug in connector to vehicle charge port. Confirm cable is fully inserted. Charging will initiate once
connected.
Step 7 Tap ‘Stop Charging’ to end the charging session.
Step 8 Once charging has stopped, unplug vehicle by pressing the release button on the connector
handle.

9
2OPERATING THE BOOST CHARGER
Step 9 Return the cable to the charging station holster.
Step 10 Tap ‘Exit’ to return to the home screen.
Note: The driver may select to plug in the vehicle first, then initiate charging on the screen. This is also
supported by the Boost Charger (Plug, Pay, Go).
2.6 LED Status Indicators
The LED Status Indicators will change depending on availability and/or status of the charger.
• Solid Green - Available for charging.
• Blinking Green - Charging session initiating.
• Red - Out of order or unavailable for charging.
• Status Level Indicator - There are two sets of LEDs per side of the unit. During charging sessions, the top
set of LED lights will fill from bottom to top to indicate the vehicle’s state of charge (SOC). The fuller the
bar, the fuller the EV’s SOC.

10
3USER INTERFACE WALK-THROUGH
3 User Interface Walk-through
3.1 Getting Started
3.1.1 Home Screen
The Boost Charger home screen has four major components to welcome the user. Two panels on the far left
and right sides of the screen specify the charger type, CHAdeMO and/or CCS, and availability. The ‘Help’ and
‘Pricing Details’ buttons on the bottom of the screen help you decide which connector to use and provides
details on the cost per charge. And the driver support phone number is in the top right corner.
3.1.2 Pricing Details
‘Pricing Details’ will show an EV driver the cost to charge at your station. As a station owner, you control
pricing and you can change it at any time by logging into your EV Connect Administrator Portal.
3.1.3 Initiate Charging
Connector availability is clearly noted under each CHAdeMO and/or CCS icon. The icons specify which side
of the unit the connectors are located. Tap the corresponding panel to initiate the charging process. A user
can simply pay, plug, go.

11
3USER INTERFACE WALK-THROUGH
3.2 Payment
3.2.1 Payment Options
After selecting connector type, users can either (a) tap an EV Connect RFID card, if they have one, or (b)
insert/swipe/tap a credit card on the reader available directly below the screen. ‘Pricing Details’ can be
accessed on this page for more information on charging rates. This pricing table is also accessible on the
home screen.
No Touch Authorization
The Boost Charger uses EV Connect to allow drivers to easily find, access, and securely pay for EV charging.
To begin your charging session, follow the steps below:
Step 1 Download and launch the EV Connect app.
Step 2 Scan the QR code or type in the Station ID.
Step 3 Plug in your vehicle and tap ‘Charge Now’.
3.2.2 Payment Processing
Once payment is initiated, Boost Charger will display information on the payment status. Selecting ‘Cancel’
will stop payment authorization and return to the home screen. If the payment authorization fails, the
message “Error Auth Failed. Please try again” will appear. Select the desired port, then insert your payment
or tap your RFID card to try again.
2.2.3 Payment Authorization
When the payment authorization is successful a screen with, “Authorization success”, will appear, then the
screen will instruct you to plug in the vehicle to initiate charging.
3.3 CONNECT TO THE EV
3.3.1 Plug in Vehicle Notification
The screen will display which connector had been selected from the home screen. Plug in the selected
connector to the vehicle. If the wrong connector was selected, tap ‘Cancel’ to return to the home screen and
begin the process again by selecting the correct connector.
3.3.2 Preparing to Charge
The Charging Start Up screen should say “Please Wait! Charging Session Starting Up” above a flashing
lightning bolt.

12
3USER INTERFACE WALK-THROUGH
3.4 Active Charging
3.4.1 Charging Screen
When charging is in progress, charging information will be displayed on the side of the screen that
corresponds with the active connector. Information includes:
• Current charge: Vehicle battery charge in percentage.
• Time elapsed: Time elapsed since charging was initiated in minutes and seconds.
• Energy delivered: Energy delivered to the vehicle in kilowatt-hours (kWh).
• Current power: Power delivered to the vehicle in kilowatts (kW).
• Total cost: Cost is contingent on the rate information provided in the ‘Pricing Details’ button available on
the home screen.
’Stop Charging’ button will end the charging session and allow safe disconnect from the vehicle.
NOTE: Do not attempt to remove the connector from the vehicle before you have selected the ‘Stop
Charging’ button. See more details in section 3.6.

13
3.5 DUAL CHARGING
Boost Charger can charge up to two EVs at once. Follow the steps below for instructions on how to connect
and charge a second vehicle.
3.5.1 Select Connector not in Use
The connector not in use will display the message “Available for charging”. Select the panel for the available
charger to initiate the charging process.
3.6 STOP CHARGING
3.6.1 Stop Charging
Charging can be stopped at any time. Simply tap the ‘Stop Charging’ button on the corresponding connector
panel. Power will stop at this time and the payment session will end.
3USER INTERFACE WALK-THROUGH

14
3.6.2 Charging Stopped
A charging stopped confirmation screen will appear the end of the charging session. It is now safe to remove
the connector from the vehicle. Tapping the ‘Exit’ button will return to the home screen.
3.7 Driver Support
If a user experiences any issues with using the Boost Charger, please contact EV Connect at (866) 816-PLUG.
3USER INTERFACE WALK-THROUGH

15
4BOOST CHARGER MAINTENANCE
4 Boost Charger Maintenance
4.1 Maintenance Overview
The FreeWire Boost Charger is designed for minimal maintenance over its lifetime. The network connection
monitors the health of the system as well as any error codes or faults. An alert is sent when corrective
maintenance or service might be required.
The Boost Charger Warranty includes preventative maintenance for the duration of the selected warranty.
While the Boost Charger is under warranty, FreeWire Technologies, or a FreeWire approved contractor, will
perform annual preventative maintenance. If additional maintenance is required, please contact EV Connect
to arrange for the required work to be completed.
Only qualified technicians or FreeWire approved personnel can perform service and/or maintenance on the
Boost Charger. Work performed by unqualified personnel can/will void the warranty on the Boost Charger.
For customer support or to schedule service and/or maintenance on the Boost Charger, please contact EV
Connect support at [phone].
4.2 Site Operator’s Responsibilities
The items below outline the responsibilities of the site or facility manager when it comes to general site
maintenance.
• In the event of smoke or fire, immediately call 9-1-1 to reach the fire department and refer to the Fire
Department Tip Sheet.
• In case of emergency, the Boost Charger can be disabled by depressing the red emergency stop button
located on the front of the unit or via a remote e-stop on site.
• If the emergency stop button on the front of the unit is accidentally engaged, pull out the button and the
unit will automatically reboot.
• Make sure that the base and vents of the Boost Charger are clear of any blockage, debris, and snow.
• Keep the area free of any standing water or blocked drainage systems/sewers.
• Check to ensure that the charge cables are returned to their holsters to prevent damage from vehicles.
• Once a month, verify that the charging cables are free from any signs of wear or damage. If a cable
appears damaged, please contact the EV Connect Site Host Support for a service visit.
• Check each station daily for vandalism or damage. If the station has been damaged, please contact the
EV Connect Site Host Support to perform service or to replace parts.
CAUTION: Do not pressure wash the Boost Charger. High pressure water spray could cause
damage to the system. Use a damp cloth to clean the Boost Charger.

16
4BOOST CHARGER MAINTENANCE
4.3 Preventative Maintenance
Preventative maintenance is included in the Boost Charger warranty. FreeWire Technologies or FreeWire
approved personnel should perform all service checks as defined below.
DANGER: RISK OF ELECTRIC SHOCK.
No user serviceable parts inside. Only authorized personnel may service this equipment. To reduce the
possibility of injury, turn main disconnect switch “OFF” and padlock before servicing equipment.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.
Preventative Maintenance, Years 1-4
• Diagnostics / Inspection
• Input air filter replacement.
• Top-off radiator fluid.
Preventative Maintenance, Year 5
• Diagnostics / Inspection
• Input air filter replacement.
• Cooling pump, 1/3 HP, 120/240 VAC replacement.
• Battery, lithium, 25.6 V (low voltage) replacement.

17
5BOOST CHARGER SPECIFICATIONS
5 Boost Charger Specifications
System
Max Output Power
CHAdeMO: 100 kW
CCS: 120 kW
Combined: charge two vehicles up to 60 kW each
Max Output Current CHAdeMO: 200 A
CCS: 300 A
Dimensions 40 in x 43 in x 96 in
Weight 3,800 lbs
Output Voltage, Charging 200 VDC – 500 VDC
Supported Connector Types CCS1 (SAE J1772™ Combo)
CHAdeMO
Charge Cable Length 140 in
User Interaction Display Full-color 24-inch LCD display for driver interaction
Authentication RFID: ISO 15693, ISO 14443, NFC
Input Rating 240 (+/- 10%) VAC, split-phase, 4-Wire, 120 A, 60 Hz
208 (+/- 10%) VAC 3-phase, WYE, 5-Wire, 80 A 60 Hz
Wiring For 240 V - 2 conductors (L1, L2) Ground
For 208 V - 4 conductors (L1, L2, L3, Neutral) Ground
Required Service Panel Breaker 150 A 240 V
100 A 208 V
Electrical Input
Interfaces

18
Safety and Compliance
Safety: Electric Vehicle
• See the EV supplier’s guide for proper care of the EV and follow directions carefully. Failure to follow
EV care instructions can results in EV explosion and property damage, severe injury, or death during
charging.
• Do not disconnect charger connector while the EV is charging.
Environmental Requirements
Location Outdoor
Operating Temperature -20° C to 55° C (-4° F to 131° F)
Storage Temperature -20° C to 55° C (-4° F to 131° F)
Operating Humidity Up to 95% at 55° C (131° F) non-condensing
Enclosure Rating IP54
5BOOST CHARGER SPECIFICATIONS
Safety Compliance U.S.: complies with UL 2202, UL 2231-1, UL 2231-2, UL 991,
UL 1973 (battery pack)
EMC Compliance U.S.: FCC part 15 Class A

19
NOTES

Any additional questions please contact:
[phone]
[e-mail]
1933 Davis St. Suite 301A
San Leandro, CA 94577
Boost Charger Operating and Maintenance Manual v1.0. 8.28.2020 Part Number 770-00005-01
www.freewiretech.com