Volt-E TW30Port User manual

VOLT-E PORTABLE DC FAST CHARGER
Model TW30Port/TW45Port/TW60Port
INSTALLATION AND
USER MANUAL
Ver
sion
1.1

P O R T A B L E D C F A S T C H A R G E R T W 3 0 P O R T / T W 4 5 P O R T / T W 6 0 P O R T
INSTALLATION AND USER MANUAL
 VOLT.E
Rua do Pinhal • 23-25
Sequeira, Braga 4715-002
Tel: [phone]
Email: [e-mail]

CONTENT
1. Important safety instructions .................................................................................... 1
1.1. Symbol Usage ............................................................................................................ 1
1.2. Safety Instructions ..................................................................................................... 1
2. Dimension ................................................................................................................... 4
2.1. Charger drawing ......................................................................................................... 4
2.2. Nameplate ................................................................................................................... 5
2.3. Product Apresentation .............................................................................................. 6
2.4. Specifications ............................................................................................................. 6
2.5. Standards ................................................................................................................. 10
3. Before Installation .................................................................................................... 12
3.1. Electrical Proteccions .............................................................................................. 12
3.2. Safety Requirements ............................................................................................... 12
3.3. Power Supply ........................................................................................................... 13
3.4. Packing List .............................................................................................................. 13
3.5. Place of Installation ................................................................................................. 14
3.6. Necessary Space ...................................................................................................... 15
4. Installation ................................................................................................................ 17
4.1. Grouding Instructions ............................................................................................. 19
4.2. Start-up ..................................................................................................................... 20
4.2.1. Verification and Inspection ........................................................................... 20
4.2.2. Switch On ....................................................................................................... 21
4.3. Output Connectors .................................................................................................. 21
4.3.1. CHAdeMO connector .................................................................................... 21
4.3.2. CCS connector (optional) ............................................................................. 22
5. Operation .................................................................................................................. 23
5.1. How to charge? ........................................................................................................ 23
5.2. Operation Sequence ................................................................................................ 26
6. Maintenance ............................................................................................................. 28
6.1. Preventive Maintenance .......................................................................................... 28
6.2. Power up Errors ....................................................................................................... 29
6.3. Connection Inspection ............................................................................................ 29

6.4. Trouble Shooting ..................................................................................................... 29
7. Technical Support .................................................................................................... 32
8. Warranty ................................................................................................................... 33
8.1. Validity ...................................................................................................................... 33
8.2. Exclusions ................................................................................................................ 33

Legal Disclaimer
COTTON CONSTELLATION LDA reserves the right to make unannounced changes
to the equipment or the equipment specifications set forth in this manual.
COTTON CONSTELLATION LDA make available to its customers the latest versions
of equipment specifications and the most up-to-date manuals on its official website
www.volt-e.pt.

Important Message
This manual contains general descriptions and technical characteristics of the performance
of the products contained herein. This document is not intended as a substitute for and is
not to be used for determining suitability or reliability of the appliance for specific user
applications.
The purpose of this manual is to provide necessary information for a safe installation,
operation and maintenance of this equipment. Read this manual thoroughly and make sure
you understand all the procedures before attempting to install or operate this equipment.
VOLT-E recommends all products of the portable DC fast charger series be installed by a
qualified electrician, and the installation must be in accordance with all applicable local and
national electrical codes and standards. Failure to observe this precaution could result in
death or severe personal injury.
For reasons of safety and to help guarantee compliance with documented system data, only
the manufacturer and its certified technicians should perform repairs to components.
VOLT-E has taken every precaution to produce an accurate, comprehensive and user-
friendly manual and will therefore assume no responsibility nor liability for direct, indirect
or accidental personal and/or material damage due to any misunderstanding or undesired
mistakes in this manual.
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of VOLT-E. The
information provided in this manual is designed to be unambiguous and used. However,
the manufacturer assumes no responsibility for its use or for any third-party rights
infrastructure that may cause its use.
All other product names or trademarks are the property of their copyright.

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1. Important Safety Instructions
SAVE THIS INSTRUCTIONS!
This manual contains important instructions for the Portable DC Fast
Charger series products TW 30 Port/TW 45 Port/TW 60 Port that
shall be followed during the installation, operation and maintenance
of each unit.
This manual is exclusively intended for the Portable DC Fast Charger series products
TW 30 Port/TW 45 Port/TW 60 Port. The pictures used in this manual are only visual
examples. The figures and explanations contained in this manual refer to only a typical
product design. The equipment that you purchased may differ in their appearance.
1.1. Symbol Usage
DANGER!
Indicates extremely important information about safety
instructions which, if not followed, will result in death or serious
injury.
ATTENTION!
Indicates important information about safety observations which,
if not followed, could result in personal injury or cause fire or
equipment overheating.
USEFUL INFORMATION
Indicates reference information for installation, operation and
maintenance which does not contain personal injury or equipment
safety related information.
1.2. Safety Instructions
The Portable DC Fast Charge is designed only for indoor use and installations. The
device must be installed securely and with appropriate safety precautions.

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Please read all instructions described in this
manual carefully before beginning the
installation process. Pay special attention to the
following precautions:
 Installation, commissioning,
maintenance or retrofitting of the
portable fast charger must be
performed by well trained and
qualified electricians who are fully
responsible for the compliance
with existing standards and
installation regulations.
 Incorrect installation and testing
of the Fast Charger could
potentially damage either the
vehicle’s Battery and/or the Fast
Charger itself Any resulting
damage is excluded of the
warranty for the Fast Charger.
 The Fast Charger must be
grounded through a permanent
wiring system or an equipment
grounding conductor.
 Do not install or use the Fast
Charger near flammable,
explosive, harsh, or combustible
materials, chemicals, or vapors.
 To avoid a risk of fire or electric
shock, do not use the Fast
Charger with an extension cord.
 Do not remove the cover or
attempt to open the enclosure of
the charging unit.
 This Fast 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.
 Turn off input power at the
circuit breaker equipped on the
fast charger before installing and
cleaning.
 The Fast Charger may only be
operated in perfect condition. Do
not use the Fast Charger if it is
defective, appears cracked,
frayed, broken or otherwise
damaged, or fails to operate.
 Do not use the Fast Charger
when either you, the vehicle, or
the Fast Charger is exposed to
severe rain, snow, electrical storm
or other severe weather
conditions.
 The Fast Charger is designed only
for vehicles that are compatible
with the CHAdeMO and CCS
(optional) charging standards.
 Use the fast charger only within
the specified operating
parameters.


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 Do not attempt to open,
disassemble, repair, tamper with,
or modify the Fast Charger,
because the Fast Charger is not
user serviceable. Please contact
VOLT-E for any repairs.
 Charging with a worn or damaged
DC connecter may cause burns
or start a fire.
 If the DC output connecter feels
hot while charging, turn off the
equipment and replace the DC
connector.
 Children should be supervised
when this product is used around
them.
 The principal difference between
these three models is the number
of charging power modules
applied in each one of them; the
TW30Port includes two charging
modules of 15 kw, the TW45Port
three and the TW60Port four.

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2. Dimension
Study carefully all drawings and make sure you have sufficient knowledge of each
functional component. Charger appearance details may vary slightly depending on
production date and model.
2.1. Charger drawing
Figure 1 VOLT-E Portable Fast DC Charger Front View

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Figure 2 VOLT-E Portable Fast DC Charger Top View
2.2. Nameplate
The nameplate is located on the back of the charger. The attached illustration
provides all the information included on the nameplate. Actual nameplate size may
vary depending on equipment variant.
Figure 3 Nameplate
1
2
3
5
6
4

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1
Manufacturer name
2
Manufacturer
adress
3
Product designation
(
may vary between
:
TW30Port or TW45Port or TW60Port)
4
Technical Data
5
Serial number
6
CE
mark
2.3. Product Apresentation
The VOLT-E Portable DC Fast Charger series is intended for fast charging all
electric vehicles with CHAdeMO and CCS compliance.
With a compact and portable design, the TW 30Port/TW 45Port/TW 60Port can
be easily installed and transported for EV charging in a variety of situations with
minimal effort. Depending on the model of your EV, this fast charging equipment
can charge all compatible batteries up to 80 in less than 30 minutes.
The latest technology of module power charging unit applied in this fast charger
makes it possible to configurate the output power from 3.7 kW to 60 kW in
accordance with the local power supply available.
The illustrative and intuitive interface demonstrates all necessary information related
to the charging status, namely the running time, the energy consumption calculated
by kWh usage and the present battery level of your EV. The default and user
configurated charging program finishes by itself or can be terminated by a user
command.
Unlike an EV charging station, only minimal personnel or financial outlay are
required for installation, making it an affordable solution for all kinds of budget.
2.4. Specifications
The principal technical data of the VOLT-E Portable DC Fast Charger line products
are indicated in the following tables These units are intended to have at least one DC
output connection (CHAdeMO and/or CCS).
Table nº 1 VOLT-E Portable 30 kW DC Fast Charger Technical Characteristics
TECHNICAL DATA 30KW

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AC NOMINAL INPUT
PHASES / LINES 3P+N+PE
VOLTAGE & FREQUENCY 380Vac ±15%; 50/60 Hz
NOMINAL INPUT CURRENT 45 A
EFFICIENCY ＞93.5%
POWER FACTOR 0.99
DC OUTPUT
VOLTAGE RANGE 50 Vdc to 500 Vdc
CURRENT RANGE Up to 75 A
NOMINAL POWER 30kW
GENERAL SPECIFICATIONS
CHARGING MODE IEC 61851-1 (Mode 4)
COMMUNICATION WITH EV CAN, PLC
DC PLUGS
JEVS G105 (CHAdeMO)
Combo T2 (CCS / Combo2)
Human machine interface
-Display
-Button
4.3 inch
Emergency button
Place of installation Indoor
Altitude ≤1000 m
Operating temperature -45ºC to +45ºC
Cooling System Fan Cooling
Humidity 5~95%

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Measures (W x D x H) 250X500X450mm
Weight 40kg
Table nº 2 VOLT-E Portable 45 kW DC Fast Charger Technical Characteristics
TECHNICAL DATA 45KW
AC NOMINAL INPUT
PHASES / LINES 3P+N+PE
VOLTAGE & FREQUENCY 380Vac ±15%; 50/60 Hz
NOMINAL INPUT CURRENT 63 A
EFFICIENCY ＞93.5%
POWER FACTOR 0.99
DC OUTPUT
VOLTAGE RANGE 50 Vdc to 500 Vdc
CURRENT RANGE Up to 110 A
NOMINAL POWER 45kW
GENERAL SPECIFICATIONS
CHARGING MODE IEC 61851-1 (Mode 4)
COMMUNICATION WITH EV CAN, PLC
DC PLUGS
JEVS G105 (CHAdeMO)
Combo T2 (CCS / Combo2)
Human machine interface
-Display
-Button
4.3 inch
Emergency button

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Place of installation Indoor
Altitude ≤1000 m
Operating temperature -45ºC to +45ºC
Cooling System Fan Cooling
Humidity 5~95%
Measures (W x D x H) 250X500X450mm
Weight 60kg
Table nº 3 VOLT-E Portable 60 kW DC Fast Charger Technical Characteristics
TECHNICAL DATA 60KW
AC NOMINAL INPUT
PHASES / LINES 3P+N+PE
VOLTAGE & FREQUENCY 380Vac ±15%; 50/60 Hz
NOMINAL INPUT CURRENT 83 A
EFFICIENCY ＞93.5%
POWER FACTOR 0.99
DC OUTPUT
VOLTAGE RANGE 50 Vdc to 500 Vdc
CURRENT RANGE Up to 150 A
NOMINAL POWER 60kW
GENERAL SPECIFICATIONS
CHARGING MODE IEC 61851-1 (Mode 4)
COMMUNICATION WITH EV CAN, PLC

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DC PLUGS
JEVS G105 (CHAdeMO)
Combo T2 (CCS / Combo2)
Human machine interface
-Display
-Button
4.3 inch
Emergency button
Place of installation Indoor
Altitude ≤1000 m
Operating temperature -45ºC to +45ºC
Cooling System Fan Cooling
Humidity 5~95%
Measures (W x D x H) 250X500X600mm
Weight 80kg
2.5. Standards
The VOLT-E Portable DC Fast Charger series products comply with the
following standards:
Technical Data
CE
Applicable Standards
Universal
IEC 60950-1
IEC 61851
-
1
Connectors
IEC 62196
-
1
IEC 62196-3
Emission
IEC 61000-6-3
IEC 61000
-
3
-
3
Immunity
IEC 61000
-
6
-
1
IEC 61000
-
4
-
3
IEC 61000
-
4
-
4

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IEC 61000
-
4
-
5
IEC 61000
-
4
-
6
IEC 61000
-
4
-
8
IEC 61000-4-11
IEC 60950-1: Safety of information technology equipment - Part 1: General requirements
IEC 61851-1: Electric vehicle conductive charging system - Part 1: General requirements
IEC 62196-1: Plugs, socket outlets, vehicle connectors and vehicle inlets
Conductive charging of electric vehicles - Part 1: General requirements
IEC 62196-3: Plugs, socket outlets, vehicle connectors and vehicle inlets
Conductive charging of electric vehicles - Part 3: Dimensional compatibility
and interchangeability requirements for d.c. and a.c/d.c pin and contact-tube
vehicle couplers
IEC 61000-6: 3 Electromagnetic compatibility (EMC) - Part 6-3: Generic
standards - Emission standard for residential, commercial and light-industrial
environments
IEC 61000-3: 2 Electromagnetic compatibility (EMC)- Part 3-2: Limits - Limits
for harmonic current emissions (equipment input current ≤16 A per phase)
IEC 61000-3: 3 Electromagnetic compatibility (EMC) Part 3-3: Limits
Limitation of voltage changes, voltage fluctuations and flicker in public low- voltage supply
systems, for equipment with rated current ≤16 A per phase and
not subject to conditional connection
IEC61000-6-1: Electromagnetic compatibility (EMC)-Part6-1: Generic Standards-Immunity for
residential, commercial and light-industrial environments
IEC61000-4-2: Electromagnetic compatibility (EMC)-Part4 2: Testing and measurement
techniques-Electrostatic discharge immunity test
IEC61000-4-3: Electromagnetic compatibility (EMC)-Part4 3: Testing and measurement
techniques-Radiated, radiofrequency, electromagnetic field immunity test
IEC61000-4-4: Electromagnetic compatibility (EMC)-Part4 4: Testing and measurement
techniques- Electrical fast transient/burst immunity test
IEC61000-4-5: Electromagnetic compatibility (EMC)-Part4 5: Testing and measurement
techniques-Surge immunity test
IEC61000-4-6: Electromagnetic compatibility (EMC)-Part4 6: Testing and measurement
techniques-Immunity to conducted disturbances, induced by radiofrequency fields
IEC61000-4-8: Electromagnetic compatibility (EMC)-Part4 8: Testing and measurement
techniques-Power frequency
IEC61000-4-11: Electromagnetic compatibility (EMC)-Part4 11: Testing and measurement
techniques -Voltage dips, short interruptions and voltage variations immunity tests

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3. Before Installation
Before any installation work is performed, study all drawings furnished by the supplier
for the installation, including arrangement drawings (front and top view) of each
functional component.
Please read this section carefully before
handling charger wiring. All instructions
below must be strictly followed.
3.1. Electrical Proteccions
To ensure full protection of the charger installation and operation against any electrical
risk, it is mandatory to install a main circuit breaker (MCB) and a residual current device
(RCD) upstream of the charger.
These electrical protections and the rest of the installation must be in accordance with
local and national rules. Selectivity of protections must be ensured throughout the
installation process.
ELECTRICAL RISK!
Take precautions to make the electrical connection inside the charger.
This device must be completely disconnected from any power source
during commissioning.
ATTENTION!
Inappropriate Operations may cause serious
property damage and avoid warranty!
3.2. Safety Requirements
 Eye protection with appropriate glasses (especially when using the electrical drill)
 During the installation, make sure to avoid direct connections with power
distribution network cables without additional protection;




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 Always ensure that no power is connected during the installation procedure;
 Use appropriate tools for each function.
3.3. Power Supply
The Portable DC Fast Charger is suggested to be connected directly to the customer
power distribution board for the best performance and safety precaution. The Portable
Fast charger requires a three-phase connection. A normal domestic or small business
power connection is NOT sufficient. Contact your electricity distributor and/or grid
owner for more information.
The size of the charger input power line must be checked by a qualified electrician. It is
important to note that various factors, such as the cable length between the distribution
board and the charging device, the maximum output current of the charging device may
affect the selected cable. In such cases the cross section may be required to adapt the
temperature resistance of the power supply line.
The technical data section provides nominal settings taken at the factory with the supply
of the maximum charger output current. If the power supply current is less than the
maximum output current, you may need to adjust the nominal current to a lower value.
For more information, refer to the detailed instructions provided in the operation
section.
Depending on the model, the recommended value may differ. Please check the
respective recommendation for the purchased model.
3.4. Packing List
Before you begin the installation process of this charger, carefully check the package you
received according to the packing list provided below. If any components described
below are not properly packaged, contact the customer service center for replacement.
Portable DC Fast Charger x1
Installation and User Manual x1
DC Cable x1
AC Supply Connection x1

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3.5. Place of Installation
For the best operating conditions and longest operating life, please take care in selecting
an installation site. Operating life and performance will be influenced by the selected
charger location.
The charger is designed for indoor use. Therefore, you must ensure the correct
configuration requirements and device protection at the place of installation.
The following criteria should be considered regarding local selection:
 It is important to study the local wiring regulations, fire prevention measures and
accident prevention regulations, as well as the escape routes from the installation
site.
 The charger may NOT be installed in potentially explosive environments.
 Install the charger so that it is not in direct pedestrian flow and so that no one
can trip over the charging cables and that the cables do not cover or cross
pedestrian and motorized traffic.
 Do not install the charger where it is exposed to ammonia or ammonia gas (for
example: stables).
 The mounting surface must be stable enough to withstand mechanical forces.
 Do not install the charger where falling objects could damage the device (for
example, ladders or suspended car tires).
 The equipment should not be exposed to direct spray water (for example:
adjacent hand wash installation, high pressure cleaner, garden hose).
 The equipment should be protected from direct rain as much as possible to
prevent freezing, hail or similar damage.
 Observe the permissible environmental conditions;
 It is recommended not to expose this equipment to high temperatures, dust,
corrosive fumes, combustible materials, or explosive gases;
 Select a dry and well-ventilated location;
 To reduce the risk of fire, install the charger on a non-combustible surface such
as concrete, stone, brick, or steel;