THERMOLEC DCC-9-PCB Electric Vehicle Energy Instruction Manual

THERMOLEC DCC-9-PCB Electric Vehicle Energy

Product Information

The Electric Vehicle Energy Management System (EVEMS) is a system designed to manage and control the energy flow between an electric vehicle charger and the power source. It is compatible with a main power supply of 120/240-208V, Single Phase, with options for 60A, 70A, 80A, 90A, 100A, and 125A. The system is approved for use in North America. The EVEMS is designed by V5.5 and is subject to copyright
protection. Any reproduction or modification of the information in this manual requires prior written authorization from THERMOLEC LTEE. All trade names mentioned in this document belong to their
respective owners and their mention in this manual does not imply sponsorship or approval of the product.

Product Usage Instructions
Safety Information

• Read all instructions prior to using this product.
• For vertical installation on a wall, refer to the enclosure information for the choice of mounting position.

Precautions

• Schedule the charging of the vehicle during hours of low electrical consumption to minimize interruptions to the electric charging station.
• This product can be installed with other types of load, not just EV chargers.
• The installer is responsible for ensuring the electric power source is appropriate for the installation.

Limited Warranty
THERMOLEC LTEE. offers a limited one-year warranty on the integrated controls of the EVEMS from the shipping date. The warranty only covers equipment and components supplied by THERMOLEC
LTEE. The warranty will be void if the product is incorrectly installed, used inappropriately, or repaired by unauthorized personnel. THERMOLEC LTEE. will repair or replace the defective material after evaluation by its representative. The company is not liable for damages, delays, or transport costs related to the allegedly defective EVEMS. Indirect damages or delays caused by faulty workmanship or materials are also not covered. Repairs, replacements, or modifications require prior written consent from THERMOLEC LTEE. Components supplied for repairs are guaranteed for the remaining warranty period or 90 days, whichever is longer. Repairs made at the THERMOLEC LTEE. the plant is guaranteed for 30 days from the date of repairs.

Specifications
The EVEMS is a DCC-9 Energy Management System designed to allow the connection of an EV Charger to a power source without affecting load calculation.

Characteristics
The EVEMS is compatible with a main power supply of 120/240-208V, Single Phase, with options for 60A, 70A, 80A, 90A, 100A, and 125A.

Conditions for Application
The EVEMS can be installed in various types of installations.

ABOUT THIS MANUAL
ERRORS AND INACCURACIES
For any inaccuracy or omission, or to forward any general comments or suggestions concerning the quality of this manual, please send an email to [email protected].

COPYRIGHTS AND TRADE NAMES
All information in this manual is subject to copyright protection and other intellectual property protection of THERMOLEC  and its licensors. This installation manual cannot be modified, reproduced or copied without prior written authorization from THERMOLEC and its licensors. Additional information is available on request. The following logos are trade names or trademarks of THERMOLEC  in the United States and in Canada.

DCC – EVENTS
All other trade names mentioned in this document are the property of their respective owners and their uses in this manual do not mean 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 that must be followed during the installation, maintenance, and application of the DCC – Electric Vehicle Energy Management System (EVEMS).

Warning
Read all instructions prior to using this product.

• Always disconnect the DCC – EVEMS power supply before any work.
• Use only the DCC – EVEMS by following the technical specifications indicated in this installation manual.
• Do not install the DCC–EEMS near 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 damage 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 on the enclosure for the choice of mounting position.

Precautions

• Any improper use of the DCC–EVEMS can cause damage 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 damage.
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 the 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 the 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 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 were made at the THERMOLEC LTÉE. plant is guaranteed for 30 days from the date of repairs.

SPECIFICATIONS

The DCC – Electric Vehicle Energy Management System (EVEMS) is a safety device with a programmable controller that protects an electrical distribution circuit in relation to its main breaker. It will prevent overloading the electrical distribution circuit by momentarily turning off the power to the charging station when the demand exceeds 80% of the main breaker rating. DCC-9-PCB is the electronic infrastructure that fits inside the DCC-9-BOX to complete a fully working DCC-9 unit.

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 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 other configurations, please contact us.

POWER OUTAGE
In the event of a power outage, the DCC – EVEMS automatically restores 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-minute 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-minute recovery time.

DCC INSTALLATION

STEP 1: CHECK THE PACKAGE CONTENTS

STEP 2: PREPARATIONS FOR INSTALLATION

1. Disconnect the main power supply from the DCC-9-BOX.
2. Remove DCC-9-BOX cover unit.
3. Unscrew two red-marked screws on the DCC-9-BOX backplate.
4. Unscrew the two wires attached to the white terminal block.
5. Unscrew the white terminal block from the backplate and displace it.
   NOTE: The white terminal block is not needed to complete the installation of the PCB.

STEP 3
MOUNTING THE PCB ON THE BACKPLATE OF THE DCC-9-BOX

1. Take the PCB unit, and clip the current transformer marked “CT1” onto the cable identified by the number “1”.
2. Clip the current transformer marked “CT2” onto the cable identified by number “2”.
3. Place the PCB unit on the backplate and into the slider, ensuring that the EV Charger Breaker is aligned with the “EV Charger 240V” sticker.
4. Fasten the PCB into place using pre-drilled holes and re-using red-marked screws onto the backplate.

STEP 4: CONNECTING THE PCB

1. Connect the L1 cable to the relay Terminal 1.
2. Connect the L2 cable to the relay Terminal 2.

STEP 5: CONDUCTOR CONNEXIONS
Consult the diagram on page 8 for all details on the cable connections configuration. This diagram is also found under the DCC cover.

STEP 6:
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):

Note : DCCs do not support configurations in which the charger circuit (EVC value) is greater than half the capacity of the electrical input (CB value). This is why, for example, the combination CB=100A, and EVC=60A prevents the DCC from being switched on (flashing red light). However, it is possible to safely operate the DCC for a 60A charging circuit on a 100A main electrical input using the following configuration that provides a 60% load shedding threshold of 125A, i.e. 75A:

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 times: 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.
3. 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
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.

LEGEND

• R POWER RELAY
• DCC  ELECTRONIC CONTROLLER
• CB CIRCUIT BREAKER
• T TRANSFORMER
• CT CURRENT TRANSFORMER

IMPORTANT
Wire in accordance with local and National Electrical codes. Read instructions carefully before wiring and operating.

CONFIGURATION DIAGRAMS

Main Circuit Breaker (Amps)

NoirSee dip switch programming step in the manual for more details

APPLICATION
Electric vehicle recovery time Following a power cut to the electric vehicle supply equipment (EVSE), a 15-minute delay is initiated to monitor the total consumption of the electrical system. Power to the vehicle will then be restored if the total load consumption is lower than 80% of the main circuit breaker rating. 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 means 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 [email protected] and then call 1 833-717-1355.

No power. Check the power source.

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