THERMOLEC DCC-9-XXA Electric Vehicle Energy Management System Installation Guide

THERMOLEC DCC-9-XXA Electric Vehicle Energy Management System

ABOUT THIS MANUAL

ERRORS AND INACURACIES

For any inaccuracy or omission, or to forward any general comments or suggestions concerning the quality of this manual, please send an email to support@rve.ca.

COPYRIGHTS AND TRADE NAMES

All information’s in this manual are subject to copyright protection and other intellectual property protection of THERMOLEC LTÉE. / RECHARGE VÉHICULE ÉLECTRIQUE and its licensors. This installation manual cannot be modified, reproduced or copied without a prior written authorisation from THERMOLEC LTÉE. / RECHARGE VÉHICULE ÉLECTRIQUE and its licensors. Additional information’s are available on request. The following logos are trade names or trademarks of THERMOLEC LTÉE. / RECHARGE VÉHICULE ÉLECTRIQUE in the United States and in Canada.

All other trade names mentioned in this document are the property of their respective owners and their uses in this manual does not means a sponsorship or approval of the product. The use of any trade name shown in this document is strictly forbidden.

In this document, the terms DCC – EVEMS and DCC are equivalent.

SAFETY INFORMATION

This document describes important safety instructions which must be followed during installation, maintenance and application of the DCC – Electric Vehicle Energy Management System (EVEMS).

Warning

Read all instructions prior using this product.

Always disconnect the DCC – EVEMS power supply before any works.

Use only the DCC – EVEMS by following the technical specifications indicated in this installation manual.

Do not install the DCC – EVEMS nearby inflammable materials, explosives or fuels, chemical products and vapors. Never spray the DCC – EVEMS with water or any other liquids.

Stop using the DCC – EVEMS immediately if defective, cracked, broken or damaged.

Never try to modify, repair or dismantle the DCC – EVEMS. Please contact the manufacturer for any malfunction.

Never insert a sharp object inside the DCC – EVEMS at the risk of causing damages to the components.

Any improper use of the DCC – EVEMS could result in serious injuries which may cause death.

For a vertical installation on a wall, refer to the information’s on the enclosure for the choice of mounting position.

Precautions

Any improper use of the DCC – EVEMS can cause damages and premature wear of the components, which voids the warranty.

Never use the DCC – EVEMS above or below the temperature range of -22 °F to 113 °F (-30 °C to 45 °C).

Only store the DCC – EVEMS above or below the temperature range of -4 °F to 158 °F (-20 °C to 70 °C).

The installation of the DCC – EVEMS must be done in accordance with the latest electrical code requirements.

Notes

It is recommended to schedule the charging of the vehicle during hours of low electrical consumption to minimize interruptions to the electric charging station.

Always check that the DCC – EVEMS is adequately fixed to the wall or ceiling or in a location to avoid any damages.

Even if this product is advertised for EV chargers, it can be installed with other types of load.

It is the installer’s responsibility to make sure that the electric power source is adequate for the use of the DCC – EVEMS.

Do not use any cleaning solvents to clean the DCC – EVEMS.

Limited warranty

1. THERMOLEC LTÉE. warrants the integrated controls against any defects for a period of one year from the shipping date. The warranty is limited to the equipment and components supplier by THERMOLEC LTÉE.

2. In case of incorrect installation, inappropriate use or repairs done by unauthorized personnel by THERMOLEC LTÉE., the warranty will be automatically void.

3. THERMOLEC LTÉE. undertakes to repair or replace, at site or at the manufacturing location, at his option, the defective material only after an evaluation made by its representative.

4. THERMOLEC LTÉE. will not be held liable for damages or delays and will not be required to pay transport cost of the EVEMS said to be defective.

5. THERMOLEC LTÉE. shall not be liable for any indirect damages or delays caused by faulty workmanship or materials.
   No indemnity will be paid for repairs, replacements or modifications without a prior written consent supplied by THERMOLEC LTÉE.

6. Any control device or accessory supplied with the DCC – EVEMS to be installed or connected remotely from the EVEMS will be guaranteed by the manufacturer only under the special conditions mentioned in paragraph 5.

7. The components supplied for repairs are guaranteed for the remaining of the warranty on the original product or 90 days. The longest period will prevail.

8. All repairs made at the THERMOLEC LTÉE. plant are guaranteed for 30 days from the date of repairs.

SPECIFICATIONS

The DCC – Electric Vehicle Energy Management System (EVEMS) is a safety device with programmable controller that can protect an electrical distribution circuit in relation with its main breaker. It will prevent overloading the electrical distribution circuit by turning off momentarily the power to the charging station when the demand exceeds 80% of the main breaker rating.

Voltage and wiring| 240/208V AC single phase:
L1, L2, Neutral, Ground.
---|---
Terminals size| up to 2/0 (CU/AL)
Frequency| 50 to 60 Hz
Operation temperature| -22°F to 113°F (-30°C to 45°C)
NEMA 3R enclosure| Dimensions (H” x W” x D”
12″ x 12″ x 7.5″
14″ x 13″ x 8″| Total weight
17 lb (7,71 kg)
18 lb (8,16 kg)

*Approximative and can change without notice. V1

CHARACTERISTICS

CONDITIONS FOR APPLICATION
The DCC-9 is an Energy Management System specially designed to allow the connection of an EV Charger to be connected to a power source without affecting load calculation.

INSTALLATIONS TYPES
Group installation, Wall installation, Ceiling installation

MAIN POWER SUPPLY (CB)
The DCC – Electric Vehicle Energy Management System (EVEMS) can be powered by a 240/208V AC single phase source.

The following options are offered by each DCC model:

SECONDARY LOAD SUPPLY (EVC)

The DCC – EVEMS will provide power to a charging station through a 30A, 40A, 50A or 60A 240/208V AC circuit breaker, L1, L2 and ground.
The DCC is equipped with a Square D circuit breaker (QUO230, QUO240, QUO250 or QUO260).

TRIP PERCENTAGE (TP)
The DCC – EVEMS is factory set to turn off the charging station if the total consumption of a service exceeds 80%. For a different configuration, see the “TP” configuration details on page 9 of this manual.

POWER OUTAGE
In the event of a power outage, the DCC – EVEMS automatically restore the power supply to the vehicle charging station when power returns.

RECOVERY TIME (RT)
Following a power cut to the electric vehicle supply equipment (EVSE), a 15 minutes delay is initiated to monitor the total consumption of the electrical power system. Power to the vehicle will then be restored if the total load consumption is lower than 80% of the main circuit breaker rating during a period exceeding the 15 minutes’ recovery time.

CONTROL BY A THIRD PARTY SYSTEM (EMS)

The DCC control board has a dry contact type input (black terminal) to be connected to a building’s energy management system.

When the contact is:

• Open, the DCC cuts the power to the charging station.
• Closed, the DCC supplies power to the charging station, provided that the main power supply of the DCC is under the only configured current.

The dry contact type output, which reproduces the state of the dry contact input, allows several DCCs to be cascaded on a single control signal.

TYPICAL INSTALLATION

NOTES
For outdoor installation, use our NEMA 3R enclosure (DCC-9-XXA-3R).

DCC INSTALLATION

STEP 1: CHECK THE PACKAGE CONTENTS

• 1 x DCC-9-XXA or 1 x DCC-9-XXA-3R

• 1 x Ceiling mounting support

• 1 x Installation manual

INSTALLATION VIDEO

To access our installation video, visit our website www.dccelectric.com

STEP 2: PREPARATIONS FOR INSTALLATION

1. Disconnect the main power

2. Select the DCC intended location.

   • The DCC can be mounted on a ceiling or on a wall
     NOTE: The DCC controller must be mounted so that the nameplate remains visible at all times.
     Do not install the DCC:

   • Outdoor, unless the DCC is ordered with our NEMA 3R enclosure.

   • In a location with high level of risk.

   • Nearby inflammable materials, explosives or fuels, chemical products and vapors.

3. Before installation, check the DCC mounting position.

Wall installation
Refer to the information on the enclosure to insure proper installation.

Ceiling installation
The installation may be done in any direction.

WARNING
Warranty automatically void if the DCC is installed incorrectly.

STEP 3: INSTALLATION

Ceiling installation

1. Remove the 4 cover screws.
2. Fix the ceiling mounting support on the DCC.
3. Lift the DCC using the ceiling mounting support.
4. Position the DCC at the intended location.
5. Fix the DCC with the anchors for the type of surface.
6. Check that the DCC is adequately fixed to the wall or ceiling.
7. Remove the ceiling mounting support.

Wall installation

1. Remove the 4 cover screws.
2. Position the DCC at the intended location.
3. Ensure that the mounting is according with the information’s on the enclosure.
4. Fix the DCC with the anchors provided for the type of surface.
5. Check that the DCC is adequately fixed to the wall or ceiling.

STEP 4: CONDUCTOR CONNEXIONS

Consult the diagram on page 9 for all details on the cable connections configuration. This diagram is also found under the DCC cover.

WARNING
The location of the terminals of the main power supply and of the panel is modified from the DCC-9 generation 2.1.
Please pay attention to the indications “L1” and “L2” in the box.

STEP 5: DIP SWITCH PROGRAMMING FOR MAIN POWER SUPPLY (CB)

1. Identify the set-up section on the DCC.
2. Set up the section as per the layout corresponding to the main power supply (CB):
   

STEP 6 (OPTIONAL): CONNECTION TO A THIRD PARTY ENERGY MANAGEMENT SYSTEM

If a third-party system is to control the DCC, see step 6 at the end of this manual.

If the DCC is not used with a third party system, do not remove the jumper connecting the two terminals of the EMS IN input to create a closed contact.

STEP 7: START-UP

DCC power supply

1. Supply electrical power to the DCC.
2. Wait ten (10) seconds.
3. Check if the relay is switched on.
4. Check the pilot light:
   GREEN at all time: compliant installation, go to the next step.
   RED: refer to the Lights code section.

Charging station power supply

1. Put the circuit breaker in the ON position.
2. Check if the electric vehicle supply equipment (EVSE) is powered:
   EVSE powered : go to the next step.
   EVSE not energized : check the charging station connections.

STEP 8: SECURE AND RE-ENERGIZE

Secure

1. Turn off the power on the DCC.
2. Put the cover back.

Re-energize

1. Supply electrical power to the DCC.

STEP 9: IDENTIFICATION

1. Register all the information of the charging station owner (address and parking space) in the space provided on the cover.
2. Register all configuration settings of the main power supply (essential load) in the space provided on the cover.
3. Register all configuration settings of the charging station in the space provided on the cover.

APPLICATION

Electric vehicle recovery time

Following a power cut to the electric vehicle supply equipment (EVSE), a 15 minutes delay is initiated to monitor the total consumption of the electrical system. Power to the vehicle will then be restored if the power required by the total of the loads is less than 80% of the main circuit breaker and if the control input for the energy management system is in the closed state (closed contact).

Electric vehicle charging time

It is recommended to schedule the charging vehicle program during hours of low electrical consumption to minimize interruptions to the electric charging station.

MAINTENANCE

Do not use any cleaning solvents to clean the DCC.

LIGHTS CODE

| The charging station is energized.
---|---
| The charging station is energized. The total load exceeds 80%. If the loads exceed 80% for a predetermined period, the charging station will be de-energized.
| The charging station is not energized. The total loads exceed 80%. The resumption time will start when the total load is lower than 80%.
| The charging station is not energized. The total load is lower than 80% and the recovery time is in progress. Each flash mean two (2) minutes before the resumption of power to the charging station. (ex: 3 flashes = 6 minutes before power to the charging station). During that period, if the total load exceeds 80%, the recovery time will restart from the beginning.
| Malfunction:

|

1. Check all connections and voltage.
2. Check the DIP switch configuration settings.
3. Check if the current transformers (CT) are properly connected and interlocked.
4. Check if the connection for the current transformers are properly connected to the PCB electronics.
5. If the problem persists, send pictures of the installation at support@rve.ca and then call 1 833-717-1355.

| No power. Check the power source.

STEP 6 (OPTIONAL): CONNECTION TO A THIRD PARTY ENERGY MANAGEMENT SYSTEM

1. If a third-party system is to control the DCC, connect the “EMS IN” input (black terminal) to the “dry contact” output of the third-party energy management system.

2. If required, connect the output (EMS OUT) to the next DCC to be controlled. The recommended cable for the control signal is a twisted copper pair, 18 gauge minimum and 14 gauge if multi-stranded.

3. For the Cristal Controls LS-100 control panel (external power management system recommended), the configuration on the Outputs tab of the configuration software should be as follows:

Cycling Number of outputs used to control DCCs.
Load kW The maximum load associated with each LS-100 output (e.g., 7.7 kW per DCC-9-40)
Min OFF (sec)   900 sec. This is the minimum amount of time a charger must remain off.
Delay ON 300 sec. This is the time between the successive activation of two outputs and corresponds to the start-up time of the charger.
Delay OFF 2 sec.
Cycle delay 7200 sec (2 hours)

For questions about other LS-100 system configuration settings, see www.cristalcontrols.com/en/support-and- resources/

MAIN POWER SUPPLY
120/240-208V, Single Phase
60A – 70A – 80A – 90A – 100A – 125A
ALIMENTATION PRINCIPALE
120/240-208V, Monophasé
60A – 70A – 80A – 90A – 100A – 125A

References

• Support / Ressources - CRISTAL CONTROLS
• protocle-communication - CRISTAL CONTROLS
• DCC Electric Vehicle (EV) Charging for Condos or Full Panel Homes
• DCC Électrique - Contrôleur de charge pour véhicule électrique

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