THERMOLEC DCC-12 Electric Vehicle Energy

Product Information

The product is an Energy Management System called DCC-12, designed by THERMOLEC LTEE. It is used to connect an EV Charger to an electrical panel that is at full capacity, eliminating the need for an expensive service upgrade. The system has a NEMA 3R enclosure approved for both indoor and outdoor installations. The main power supply for the system is 240-208V AC single phase, with options for 60A, 70A, 80A, 90A, 100A, 125A, 150A, or 200A. It is approved for use in North America. The system is designed to be installed with other types of loads as well, not just EV chargers. It comes with a limited warranty of one year from the shipping date, provided by THERMOLEC LTEE. The warranty covers defects in the equipment and components supplied by THERMOLEC LTEE., but will be void if there is incorrect installation, inappropriate use, or repairs done by unauthorized personnel. The specifications of the system include a voltage rating of 240/208V AC single phase, with L1, L2, Neutral, and Ground wiring connections. The system is designed for use in NEMA 3R enclosures. The wire gauge size can accommodate up to 250 kcmil (MCM) wiring. The dimensions of the system are approximately 11 inches in height, 8 inches in width, and 5 inches in depth. The total weight of the system is approximately 8 lb (3.63 kg), but these measurements are approximate and subject to change without notice.

Product Usage Instructions

1. Read all instructions prior to using the product.
2. If installing the system vertically on a wall, refer to the information on the enclosure for the choice of mounting position.
3. It is recommended to schedule the charging of the vehicle during hours of low electrical consumption to minimize interruptions to the electric charging station.
4. The system can be installed with other types of loads, not just EV chargers.

Note: It is the installer’s responsibility to ensure that the electric power source is appropriate for the system and to follow all safety guidelines and regulations.

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 authorization 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.

DCC – EVEMS
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 da-mages 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 war-ranty.
• 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

• 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.
• In case of incorrect installation, inappropriate use or repairs done by unau-thorized personnel by THERMOLEC LTÉE., the warranty will be automati-cally void.
• THERMOLEC LTÉE. undertakes to repair or replace, at site or at the manufactu-ring location, at his option, the defec-tive material only after an evaluation made by its  representative.
• 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.
• 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 wit-hout a prior written consent supplied by THERMOLEC LTÉE.
• Any control device or accessory sup-plied 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.
• The components supplied for repairs are guaranteed for the remaining of the warranty on the original product or 90 days. The longest period will pre-vail.
• 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.

CHARACTERISTICS

CONDITIONS FOR APPLICATION
The DCC-12 is an Energy Management System specially designed to allow the connection of an EV Charger, in a house or dwelling, to an electrical panel that is at full capacity and would otherwise need to have an expensive service upgrade.

OUTDOOR INSTALLATION
The DCC-12 has a NEMA 3R enclosure approved for indoor and outdoor installations.

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 depending on EV charger breaker:

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-12 is NOT equipped with an internal breaker. The breaker to protect the branch circuit needs to be provided by the installer.

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 10 of this manual.

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 energy management system.

When the contact is:

1. Open, the DCC cuts the power to the charging station.
2. 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

DCC INSTALLATION

STEP 1: CHECK THE PACKAGE CONTENTS

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.
   Select an intended location preferably less than 25 feet away from the electric panel (power source). The current transformers supplied have a wiring of 25 feet in length, but can be extended (see the section Step 4: Conductor connexons for the extension details).
   The DCC can be mounted:

   • on a ceiling

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

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

WARNING
Warranty automatically void if the DCC is installed incorrectly.

STEP 3: INSTALLATION 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 10 for all details on the cable connections configuration. This diagram is also found under the DCC cover.

Current transformers (CT) installation and connections

1. Open the CT.
2. Install the CT around the main power cable of the panel.
3. Check the correct polarity on the CTs.
4. Connect the CT cables provided for this purpose to the terminal blocks (green terminal) on the DCC-12 control board.

EXTENSION OF CURRENT TRANSFORMERS’S WIRE
The DCC comes with 25 feet of wire. It is possible to extend the wiring supplied with the current transformers. Additional wire must be 300V rated, minimum 18 AWG (1mm), 4 conductors shielded twisted (ex: FT4 SHIELD. 4C FAS

18 or equivalent).

STEP 5-A:
DIP SWITCH PROGRAMMING FOR MAIN POWER SUPPLY

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

STEP 5-B:
DIP SWITCH PROGRAMMING FOR EV CHARGER (EVC)

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.  Identify the branch circuit breaker.
2. Register all configuration settings of the charging station in the space provided on the cover.

LEGEND

• R POWER RELAY
• DCC ELECTRONIC CONTROLLER
• T TRANSFORMER
• CT CURRENT TRANSFORMER

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

CONFIGURATION DIAGRAMS

Trip Delay: 15 seconds (Default)

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:
  • Check all connections and voltage.
  • Check the DIP switch configuration settings.
  • Check if the current transformers (CT) are properly connected and interlocked.
  • Check if the connection for the current transformers are properly connected to the PCB electronics.
  • 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:

4. • 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/

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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