FREEWIRE Boost Charger User manual

Boost Charger™
DC Fast Charging Station
Installation 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.

Boost Charger
DC Fast Charging Station
Installation Guide
Version 1.0
Table of Contents
BEFORE YOU START.................................................................................................................................. 6
GENERAL WARNINGS ............................................................................................................................... 7
SAFETY SHUTDOWN ................................................................................................................................ 7
1 OVERVIEW ............................................................................................................................................ 8
Boost Charger Components .................................................................................................................................. 8
Boost Charger Main Component Overview ...................................................................................................... 9
Circuit Breakers.......................................................................................................................................................... 11
Unlocking and Locking the Front Access Door ............................................................................................... 12
Installation Overview................................................................................................................................................ 13
Concrete Pad Installation........................................................................................................................................ 13
Preparation .................................................................................................................................................................. 14
Boost Charger Shipping Crates ............................................................................................................................ 14
Boost Charger Overall Dimensions ..................................................................................................................... 15
Equipment Needed.................................................................................................................................................... 16
2 INSTALLATION OF THE BOOST CHARGER .................................................................................. 17
Overview of Steps ..................................................................................................................................................... 17
Uncrating the Boost Charger ................................................................................................................................. 18
Mounting the Boost Charger.................................................................................................................................. 24
Grounding Requirements ........................................................................................................................................ 26
Optional External Safety Shutoff Switch............................................................................................................ 26
Connecting Electrical Power.................................................................................................................................. 28

Powering on the Boost Charger............................................................................................................................ 29
Commissioning the Boost Charger...................................................................................................................... 30
Complete a Test Charging Session...................................................................................................................... 30
3 BOOST CHARGER SPECIFICATIONS ............................................................................................. 32

6
BEFORE YOU START
This guide contains important instructions that must be followed to ensure safe installation of the FreeWire
Boost Charger® DC fast charging station. Be sure to complete the steps outlined in the Boost Charger Site
Preparation Guide (770-00004-01) prior to installing the Boost Charger.
SAVE THESE IMPORTANT SAFETY INSTRUCTIONS
Save these instructions, as they contain important information that must be followed during installation or
used for future reference of a FreeWire Boost Charger DC fast charging station.
Grounding instructions
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 and be connected to the
equipment grounding terminal or lead on the Electric Vehicle Supply Equipment (EVSE). Connections to the
EVSE shall comply with all applicable codes and ordinances.
Symbols used in this installation 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

7
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.
Safety Shutdown
The FreeWire Boost Charger can be shut down to disconnect the internal battery from the rest of the
system. The red safety shutdown button on the front of the Boost Charger activates the safety shutdown.
An external shutdown button may also be installed, given proper labeling. See the section titled “Optional
External Safety Shutdown Switch”, page 25.
To put the system into safety shutdown mode, press the red button on the front of the charger. The user
interface will then indicate that the charger is unavailable and the indicator lights will turn red.

8
1 Overview
To ensure the successful installation of the FreeWire Boost Charger® DC fast charging station, please
be sure to read this overview and become familiar with the Boost Charger and the necessary tools and
equipment to install it.
NOTE: The FreeWire Boost Charger must be installed by a licensed contractor and a licensed
electrician.
Boost Charger Components
Display
Safety Shutdown
Button
Status
Indicators
CHAdeMO/CCS
Plug & Cable
Wireless
Antenna
Area Light
RFID Card Reader
with Payment Terminal
1OVERVIEW

9
1OVERVIEW
Boost Charger Main Component Overview
Circuit Breakers
Internet Connection
(optional)
Remote e-Stop
Connection
Grid AC Connections
Ground Connection
Heat Exchanger
DC/DC Converters
Circulating Pump
Battery Cooler/
HVAC
Battery Stack

10
1OVERVIEW
Contactor Box
Upper Low-Voltage
Shelf
Lower Low-Voltage
Shelf
AC/DC Battery
Charger
Energy Meters
CCS/CHAdeMO EV
Charger Controllers
Low Voltage Fuse
Board
Programmable Logic
Controller
Power Supplies

11
1OVERVIEW
Low Voltage
Battery
Battery Management
System
Cellular Modem
Computer Processor
Circuit Breakers
1 2 3 4 5 6 9
8
Breaker Function
1 Main AC contactor
2 AC/DC battery charger 1
3 AC/DC battery charger 2
4 Battery air conditioning
5 Liquid cooling system pump
6 24 V system power supply
8 Computer processor power
9 Battery heaters
Located on the upper
low-voltage shelf

12
1OVERVIEW
Unlocking and Locking the Front Access Door
In order to unlock/lock the Boost Charger front access door, the locks behind the CHAdeMO and CCS
charge cables must be accessible.
Step 1 Remove the CHAdeMO charge cable from its respective holder.
Step 2 Insert the key and turn to unlock.
Step 3 Remove the key.
Step 4 Insert the door tool and pull open the hasp.
Step 5 Remove the door tool.
Step 6 Repeat steps 1-5 for the second lock behind the CCS charge cable.
To lock the front access door, repeat the steps in reverse order.

13
Installation Overview
Installing the FreeWire Boost Charger requires three people and takes approximately two hours. The
following steps are required for installation:
Step 1 Schedule commissioning a week prior to installation. Please reference the section titled
‘Commissioning the Boost Charger’ in section 2.
Step 2 Confirm that the site is ready per the Boost Charger Site Preparation Guide, and all required
equipment and tools are available.
Step 3 Install the FreeWire Boost Charger as described in section 2.
Step 4 Power on and activate the FreeWire Boost Charger as described in section 2.
Note: Always check local codes and requirements to ensure that the installation is compliant.
Concrete Pad Installation
The FreeWire Boost Charger must be installed on a concrete pad. Details can be found in the FreeWire Boost
Charger Site Preparation Guide (Part Number 770-00004-01). Before proceeding, make sure the conduit is
plumb and the concrete pad is properly prepared, free of debris, level, and cured.
Note: Ensure that the concrete pad is level. If not, be sure to use the proper concrete grinding tools
to remove any bumps in the concrete.
Concrete Pad
Mounting Bolts with
Protective Caps (x8)
Signal / Remote
Shut off Conduit
Main Electrical
Conduit
1OVERVIEW

14
Preparation
Before beginning the installation:
1. Check that the concrete pad is level and cured.
2. Verify that the service wiring, circuit protection, and metering complies with local codes/regulations and
is ready per the Boost Charger Site Preparation Guide (Part Number 770-00004-01)
3. Ensure the grounding conductor is properly grounded and complies with local codes.
4. Confirm there is a strong cellular signal available. The Boost Charger requires a cellular network. Install
repeaters if the signal is below -110 dBm or if the signal is intermittent. A hard-wired internet connection
can be used if there’s no cellular signal available.
5. Check to make sure that the area is safely marked off and has enough space available for tooling,
shipping crates, lifting equipment, and work trucks.
6. Confirm that all parts, tools, and equipment are available.
7. Become familiar with the entire Boost Charger installation process.
Important: In geographic areas that experience frequent thunderstorms, a supplemental surge
protection breaker must be installed at the service panel.
Boost Charger Shipping Crates
The FreeWire Boost Charger ships in one crate. The Boost Charger Mounting Template ships separately.
Caution: Transport and store the FreeWire Boost Charger in its original packaging. A forklift or
crane must be used when handling the equipment. Ensure proper load rating of equipment before
beginning.
Caution: When using a crane, make sure that the straps and cables are rated for the weight of the
Boost Charger and crates.
Approximate Dimensions Approximate Crated Weight Contents
65” x 46.5” x 102” 4,100 lbs Boost Charger
48” x 40” x 20” 100 lbs Mounting Template
1OVERVIEW

15
Boost Charger Crate Packing List
• Boost Charger
• Door access keys (2x)
• Door Tool
Boost Charger Overall Dimensions
1OVERVIEW

16
Equipment Needed
• Forklift (5,000lb capacity minimum) or crane (5,000lb capacity minimum) with nylon lifting straps and
four-point lifting sling
• Forklift tyne extensions (as required)
• 15/16” wrench and socket
• #2 Phillips screwdriver
• T27 tamper proof pin-in Torx driver and bit
• 15/16” Crows foot wrench
• Torque wrench (200 ft-lbs)
• Torque wrench (100 in-lbs)
• 2 AWG lug (grounding the service wire and earth ground)
• Zip ties (as necessary)
• Standard electrical equipment such as wire cutter, wire stripper, cable ties, conduit seal, etc.
• Band cutter
1OVERVIEW

17
2 Installation of the Boost Charger
The steps outlined in this procedure require the use of a forklift or
crane to lift, move, and mount the Boost Charger. A crane setup
using a four-point sling, similar to the example pictured to the
right, may be used in situations when a forklift cannot be used for
installation. It is recommended that the crane and four-point sling
are certified and capable of carrying at least 5,000 lbs.
When using a crane, be sure to check for height restrictions and
clearances around the work area. Any cables, nylon straps, hooks,
and shackles should be laid out to support the Boost Charger
and prevent it from swaying or tilting. Pay specific attention to the
Boost Charger’s center of gravity to avoid the unit from falling. Add
additional nylon straps and sling pick up points around the front
and back of the unit to keep it from swaying or shifting.
Warning: Improper lifting of the Boost Charger may result
in severe damage or injury.
Caution: The Boost Charger is not designed to be lifted
from the top or sides by a crane or lifting straps. Only lift
the Boost Charger from the bottom.
As needed, add chaff protection between the straps and the
Boost Charger.
Overview of Steps
• Uncrating the Boost Charger (page 17)
• Mounting the Boost Charger (page 23)
• External Safety Shutoff (page 25)
• Connecting Electrical Power (page 26)
• Installing the Kick Panels (page 27)
2INSTALLATION OF THE BOOST CHARGER

18
Uncrating the Boost Charger
Step 1 Lift the crate using a forklift or crane and place it vertically on level ground in front of the installation
pad.
Warning: Due to the size and weight of the Boost Charger, care should be taken when lifting to
prevent tipping.
Note: If a wall is located behind the installation pad, ensure the forklift tynes don’t protrude too far that they
hit the wall when moving the Boost Charger onto the pad.
Uncrating the Boost Charger is a two-person job. Make sure there is ample space to safely work around the
crate and remove the side panels. Follow the steps below to uncrate the Boost Charger.
Caution: Use care when opening the crates and removing the protective plastic wrapping to avoid
damaging the charger and charging cables.
Step 2 Carefully cut the steel strapping from the crate using a band cutter.
2INSTALLATION OF THE BOOST CHARGER

19
Step 3 Remove the bolts from the side panel.
Step 4 Release the six side and two top hasps which are used to hold the side panel of the shipping crate.
2INSTALLATION OF THE BOOST CHARGER

20
Step 5 Using two people, carefully remove the side panel from the shipping crate as shown.
Step 6 Using two people, carefully slide the remaining four panel structure away from the Boost Charger.
2INSTALLATION OF THE BOOST CHARGER