FREEWIRE Boost Charger Operating instructions

Boost Charger™
DC Fast Charging Station
Site Preparation Guide
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.

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.

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Boost Charger
DC Fast Charging Station
Site Preparation Guide
Version 1.0
Table of Contents
GENERAL WARNINGS ............................................................................................................................... 6
1 INTRODUCTION................................................................................................................................... 7
Boost Charger Overview ......................................................................................................................................... 7
Before You Start ......................................................................................................................................................... 8
Grounding Requirements ........................................................................................................................................ 8
Surge Protection ........................................................................................................................................................ 8
Lightning Protection ................................................................................................................................................. 9
ADA Considerations ................................................................................................................................................. 9
Tools and Materials.................................................................................................................................................... 9
Concrete Mounting Template ................................................................................................................................ 10
2 PREPARING THE MOUNTING PAD .................................................................................................. 11
Overview of Steps ..................................................................................................................................................... 11
Run the Conduit and Cable..................................................................................................................................... 11
Assemble the Mounting Template........................................................................................................................ 12
Mounting Specifications ......................................................................................................................................... 14
Vehicle Impact Protection....................................................................................................................................... 15
AC Conduit ................................................................................................................................................................... 15
Install the Concrete Mounting Template ............................................................................................................ 16
3 BOOST CHARGER SPECIFICATIONS ............................................................................................. 17

6
Symbols used in this site preparation guide
WARNING: This indicates a fact or feature very important for the safety of the user to prevent injury
or death and/or which can cause serious hardware damage if not applied appropriately.
CAUTION: Identifies information to prevent damage to this product.
GROUND: Earth ground symbol.
General Warnings
SHOCK RISK: HIGH VOLTAGE ELECTRICITY.
WARNING: To reduce the risk of injury, read all instructions and caution markings before installing
the FreeWire Boost Charger.
WARNING: The FreeWire Boost Charger must be installed by licensed technicians and in
accordance with all instructions.
WARNING: Installation must be done in accordance with all local electrical codes and/or the
National Electrical Code® (NEC®).
WARNING: Protection against lightning surges in accordance with local electric codes are the
responsibility of the installer.
WARNING: To reduce the risk of injury, be sure to follow lockout/tagout practices and procedures to
safeguard workers from unexpected energization.

7
1 Introduction
This guide describes how to prepare your installation site for the FreeWire® Boost Charger™ DC fast charger.
Read this document first to become familiar with the details and ensure that you have all the necessary tools
and materials to prepare the Boost Charger Concrete Mounting Pad.
Important: Always check local codes or consult an engineer to ensure that the site is prepared in
compliance with all applicable codes.
To ensure the successful installation of the Boost Charger DC fast charging station, please be sure to read
this overview and become familiar with Boost Charger and the necessary tools and equipment to install it.
Note: The FreeWire Boost Charger must be installed and serviced by a licensed installer.
Boost Charger Overview
Display
Safety Shutdown
Button
Status
Indicators
CHAdeMO/CCS
Plug & Cable
Wireless
Antenna
Area Light
RFID Card Reader with
Payment Terminal
1INTRODUCTION

8
Before You Start
Check the cellular strength at the installation site before beginning. The Boost Charger communicates using
a cellular network. FreeWire recommends that the signal is -110 dBm or better. Install repeaters if the signal
is too low or if the signal is intermittent.
You can measure signal strength using a signal meter device, or by initiating a strength test using a field test
mode on your smartphone. Instructions for this differ by smartphone, carrier, and operating system. As of
July 2020, a set of instructions can be found at: https://support.weboost.com/hc/en-us/articles/206521937-
Finding-Your-Phone-s-Signal-Strength-Reading-Field-Test-Mode-
Verify that the installation site has service wiring that meets the Boost Charger’s power requirements. Please
reference section 3.
Make sure that the grounding conductor is installed properly and complies with local codes.
Important: In geographic areas that experience frequent thunder storms, a supplemental surge protection
breaker must be installed at the service panel.
Consult NEC Article 625 Electric Vehicle Charging and Supply Equipment Systems regarding the
installation of a disconnect switch.
Grounding Requirements
The FreeWire Boost Charger must be grounded. Use a grounded, metal, permanent wiring system that runs
with circuit conductors and connects to the charger equipment ground on the Boost Charger. An
earth ground that complies to local codes must also be used for the Boost Charger.
Earth Ground
Check with local codes and regulations to determine if an earth ground is required at the physical location of
the concrete installation pad. If not, the earth ground from the electrical switch gear can be used to ground
the Boost Charger.
Surge Protection
Please refer to NEC Article 625 for installation requirements and review the installed jurisdiction for any
other electrical requirements or codes. Input over current protection needs to be provided by the installer. In
addition, it is recommended to install a UL1449 Type 1 Surge protection device (SPD) for use with the Boost
Charger, especially in areas that experience frequent thunderstorms. The specifications for the exact SPD
must be determined by a licensed electrical engineer or contractor and will depend on local laws, safety and
electrical regulations.
1INTRODUCTION

9
1INTRODUCTION
Lightning Protection
In geographic areas that experience frequent thunderstorms, it is recommended to install one electrode
(ground rod) near the Boost Charger foundation. This is dependent on the local regulations and should be
determined by the contractor. It may be necessary to consult a local specialist for the options of lightning
protection. The Boost Charger must be within the protection angle of the lightning distraction device, which
must be determined by the owner and local specialist. The implementation of the lightning protection
depends on the local laws, safety and electrical regulations.
ADA Considerations
Check with local codes and regulations to determine if the Standards for Accessible Design for Americans
with Disabilities is applicable when choosing the location and placement of the Boost Charger.
“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).” 1
Tools and Materials
Before you start, you will need the following tools and materials:
• Digging tools (shovel, spade, etc.)
• Concrete framing materials
• Concrete
• Rebar
• Conduit (See section 2 for size guidance)
• 15/16” wrenches (x2)
• Pliers to make any adjustments to the template (if needed)
• Bubble or digital level
• Concrete Mounting Template (820-00255-01)
• Torque wrench (200 ft-lb)
1 http://www.ada.gov/2010ADAstandards_index.htm

10
Concrete Mounting Template
The Mounting Template ships separately, prior to the Boost Charger. Please contact FreeWire to coordinate.
The site must be prepared by running conduit and building a concrete mounting pad. Use the FreeWire
Technologies Boost Charger Concrete Mounting Template (820-00255-01) for the mounting pad. The
mounting template will correctly align the mounting bolts and conduit to ensure that the Boost Charger can
be easily positioned.
The mounting template includes the following hardware:
• 5/8-11 UNC high strength rod thread bolts (x8)
• 5/8-11 nuts* (x32)
• 5/8-11 locking nuts (x8)
• 5/8-11 washers* (x40)
• 5/8 plastic caps (x8)
*You will need only 32 of the 5/8-11 nuts and washers when assembling the Concrete Mounting Template.
The remaining 8 are needed when securing the Boost Charger to the mounting pad as described in the
Boost Charger Installation Guide.
1INTRODUCTION

11
2PREPARING THE MOUNTING PAD
2 Preparing the Mounting Pad
This section provides instructions on how to prepare the mounting pad.
Overview of Steps
• Run the Conduit and Cable (page 11)
• Assemble the Mounting Template (page 12)
• Install the Mounting Template (page 16)
Run the Conduit and Cable
Boost Charger service wiring must be installed underground by means of conduit in compliance with local
electrical codes. When calculating the grade, type, and size of the conduit, consult local codes. The outer
diameter of the conduit must not exceed 2.5 inches for the AC power and 0.9 inches for the remote shutoff.
Typical trade size for the AC power conduit is 2 inches and 0.5 inches for the remote shutoff conduit. The
terminals in the Boost Charger are designed to use up to 2 AWG wire. The remote safety shutoff terminals
are designed to use up to 20 AWG wire. The service wiring should not be pulled until the Boost Charger is
securely mounted. This will avoid damage to the wiring during installation of the Boost Charger. The conduit
should extend 8.0” above the surface of the concrete.
Important: The Boost Charger power distribution panel is designed to work with 2 AWG wires. If
using a larger gauge wire to accommodate a long run, reduce the wire size at the disconnect.
Important: Check that the bolts fit properly into the mounting template.
Important: Check that the conduit fits properly into the mounting template before running the
conduit.
Important: The service wiring should not be pulled until the Boost Charger is securely mounted.
This will avoid damage to the wiring during installation of the Boost Charger.

12
Assemble the Mounting Template
2PREPARING THE MOUNTING PAD
*dimensions are in inches
Conduit
Feed

13
2PREPARING THE MOUNTING PAD
The AC conduit enters the opening from the front of the Boost Charger. Follow the steps below to assemble
the mounting template:
Step 1 Insert one bolt into one of the bolt holes of the top plate of the template.
Step 2 Be sure to thread the additional bolts and install the washers before passing the bolt through the
bottom plate of the template.
Step 3 Save the locking nuts (x8) and washers (x8) for installation of the Boost Charger once the concrete
is cured.
Step 4 Completely install the plastic cap down on the bolt. Then, holding the bottom nut and washer flush
against the top surface of the bottom plate, thread the bolt onto the nut until the distance between
the bottom of the plastic cap and surface of the top place is 2.3”.
Step 5 Repeat Steps 1 through 3 for the remaining seven bolts.
Step 6 Secure a second washer and nut onto the bottom of each bolt until flush with the bottom surface of
the bottom plate. Tighten each nut to 50 ft-lb.
Press the plastic cap fully
down onto the bolt
Distance should be 2.3”
Hold the bottom washer
and nut against the top
surface of the bottom plate
while adjusting the bolt
Concrete surface
3.8”

14
Mounting Specifications
Stay out zones and maintenance access points are indicated by hashed lines.
The following details are all shown in inches. Bollard locations are recommendations only and should be
determined based on the site selection, local codes, and ADA constraints.
2PREPARING THE MOUNTING PAD

15
2PREPARING THE MOUNTING PAD
Vehicle Impact Protection
Important: When installing bollards or other barriers, be sure to verify the stay out zones identified in
the mounting specifications on page 14.
It is recommended to protect the Boost Charger against vehicle impact damage when located in the path
of a vehicle or in a parking lot. Check with local and state codes or the International Fire Code® (IFC®) to see
if the installation of the Boost Charger will require bollards. If bollards are not required, it is recommended
that the Boost Charger be protected from impact from vehicles by means of curbs, fences, railings or
similar barriers. Where bollards are used, they shall be no less than 5 feet long with 2 feet below ground and
encased in concrete. Posts shall be no less than 4 inches in diameter and be filled with concrete if the wall
thickness is less than that of standard pipe. Posts shall be 4 feet apart on centers (maximum) and placed
outside all clearance areas. Other materials may be used and shall provide equivalent protection. Such curbs
or fences shall be arranged so they will not hamper free ventilation around the Boost Charger or interfere
with the ADA accessibility and service of the charger in the mounting specification.
AC Conduit
1.81
Lifting Surface
Concrete
Pad
Boost Charger
5/8-11 UNC
HIGH STRENGTH
ROD
Conduit
1.81
Lifting Surface
Concrete
Pad
Boost Charger
5/8-11 UNC
HIGH STRENGTH
ROD
Conduit
1.5
1.81
Lifting Surface
Concrete
Pad
Boost Charger
5/8-11 UNC
HIGH STRENGTH
ROD
Conduit
8.0
1.81
Lifting Surface
Concrete
Pad
Boost Charger
5/8-11 UNC
HIGH STRENGTH
ROD
Conduit

16
Install the Concrete Mounting Template
Dig an opening to accommodate the wiring conduit and the concrete mounting pad.
Step 1 Excavate the site making room for the concrete foundation pad that meets local codes and
requirements.
Step 2 Construct a concrete form for the concrete foundation pad.
Important: Make sure that the conduit is positioned within 1/16” of the opening in the mounting
template and is plumb. The conduit should extend 8.0” above the concrete surface.
Step 3 Position the concrete mounting template so that the word “FRONT” is facing up and is placed where
the front of the charging station will be located.
Step 4 Slide the concrete mounting template over the conduit. For proper installation of the Boost Charger,
the top surface of the template must be positioned 2.3” below the top surface of the concrete when
poured. Use the bottom of the plastic caps to align with the surface of the concrete. Avoid flexing
the conduit while placing the concrete mounting template. Ensure that the conduit is plumb and the
concrete mounting template is level.
Important: Secure the concrete mounting template and conduit prior to pouring the concrete. While
pouring the concrete and during the cure, it is important to prevent them from rising or floating out
of position.
Step 5 Pour the concrete into the form ensuring that it is level and does not contain any rough portions or
irregularities.
2PREPARING THE MOUNTING PAD

17
3BOOST CHARGER SPECIFICATIONS
3 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
3BOOST CHARGER SPECIFICATIONS
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
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 Site Preparation Guide v1.0. 8.24.2020 Part Number 770-00004-01
www.freewiretech.com