FREEWIRE EVBOOST01 Boost Charger DC Fast Charging Station Instruction Manual
- June 5, 2024
- FREEWIRE
Table of Contents
FREEWIRE EVBOOST01 Boost Charger DC Fast Charging Station
INTRODUCTION
Introduction
This manual describes how to operate and maintain the FreeWire Boost Charger
DC fast charging station and is intended for use by a station owner or
facility manager.
Overview
Boost Charger is equipped with a 24-inch ruggedized touch screen that meets
ADA accessibility requirements. A credit card terminal with NFC and RFID
capabilities, as well as an emergency stop button, are located prominently
below the screen.
Operating the Boost Charger
Powering on the Boost Charger
There is an emergency stop button, however there is no separate on/off switch
for the Boost Charger.
Note: The emergency stop button should not be used as an on/off switch.
The Boost Charger fast charging station is powered on during the installation
by energizing the site’s electrical panel. Immediately after completing
installation and the electrical breaker is turned on, the system will turn on
and run a series of self-tests to ensure safe operation.
These tests include:
- Electrical component safety checks
- Lighting and display checks
- Battery charging system checks
- Component operation checks (such as fans, pumps, and contactors)
- Cellular connectivity checks
If any errors are found, the display will report that the charger is not available for use and the indicator lights will turn red. Contact EV Connect at 888-780-0062 for assistance.
Shutting Down the Boost Charger
The Boost Charger only needs to be powered off during service by using the
electrical breaker at the main panel. Otherwise, there is no separate power
switch. No components will be damaged when the power is shut off, as the
system is designed to be shut off by the breaker. Also, there is no need for
any software commands to turn off the station.
The Boost Charger has the ability to be turned off by use of a remote shut off
switch. See the Boost Charger Installation Guide for more details. Whether
this feature is used and where the switch is located varies by site.
IMPORTANT: Only qualified technicians or FreeWire approved personnel are
able to complete the installation of, or perform service on a Boost Charger.
For more information please visit
www.freewiretech.com
DANGER: RISK OF ELECTRIC SHOCK.
Before beginning any work on the Boost Charger, the power must be disconnected
at the service panel. Standard practice must be followed as well as local
codes to de-energize the circuit. Standard lock out/tag out procedures should
also be followed. It is recommended to use a multimeter to test that the power
is off before service. The power should remain off for the Boost Charger until
all service doors and panels are properly reinstalled and the work is
completed.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF
LIFE.
Configure System Behavior
The site manager and/or station operator has the ability to customize a number
of the Boost Charger software features. These include:
- Setting pricing for electric vehicle (EV) drivers
- Set different pricing/access policies for different groups
To configure or make changes to settings at any time, log in to your EV Connect Administrator Portal by
visiting https://ops.evconnect.com/admin/login
For assistance with the Administrator Portal, please contact the EV Connect Site Host Support line by calling
888-780-0062.
User Interface Branding
The Boost Charger user interface (UI) has space available for custom branding,
promotions, etc. Contact
FreeWire at marketing@freewiretech.com for more
information.
Charging an EV
Pay, Plug, Go.
- Park vehicle as close as possible to available charge port. Connector type and location of charge port varies by vehicle model. Refer to individual vehicle owner’s manual for specifications.
- Open vehicle charge port.
- Use the Boost Charger’s touchscreen to start charging. Select the plug on the screen that corresponds to the port you wish to use. For an in-depth walk-through of the user interface, see section 3.
- Complete payment prompts.
- Press the button on the selected connector handle to release cable from the holster.
- Plug in connector to vehicle charge port. Confirm cable is fully inserted. Charging will initiate once connected.
- Tap ‘Stop Charging’ to end the charging session.
- Once charging has stopped, unplug vehicle by pressing the release button on the connector handle.
- Return the cable to the charging station holster.
- Tap ‘Exit’ to return to the home screen.
Note: The driver may select to plug in the vehicle first, then initiate charging on the screen. This is also
supported by the Boost Charger (Plug, Pay, Go).
LED Status Indicators
The LED Status Indicators will change depending on availability and/or status
of the charger.
- Solid Green – Available for charging.
- Blinking Green – Charging session initiating.
- Red – Out of order or unavailable for charging.
- Status Level Indicator – There are two sets of LEDs per side of the unit. During charging sessions, the top set of LED lights will fill from bottom to top to indicate the vehicle’s state of charge (SOC). The fuller the bar, the fuller the EV’s SOC.
USER INTERFACE WALK-THROUGH
User Interface Walk-through
Getting Started
Home Screen
The Boost Charger home screen has four major components to welcome the user.
Two panels on the far left and right sides of the screen specify the charger
type, CHAdeMO and/or CCS, and availability. The ‘Help’ and ‘Pricing Details’
buttons on the bottom of the screen help you decide which connector to use and
provides details on the cost per charge. And the driver support phone number
is in the top right corner.
Pricing Details
‘Pricing Details’ will show an EV driver the cost to charge at your station. As a station owner, you control pricing and you can change it at any time by logging into your EV Connect Administrator Portal.
Initiate Charging
Connector availability is clearly noted under each CHAdeMO and/or CCS icon.
The icons specify which side of the unit the connectors are located. Tap the
corresponding panel to initiate the charging process. A user can simply pay,
plug, go.
Payment
Payment Options
After selecting connector type, users can either (a) tap an EV Connect RFID
card, if they have one, or (b) insert/swipe/tap a credit card on the reader
available directly below the screen. ‘Pricing Details’ can be accessed on this
page for more information on charging rates. This pricing table is also
accessible on the home screen.
No Touch Authorization
The Boost Charger uses EV Connect to allow drivers to easily find, access, and
securely pay for EV charging. To begin your charging session, follow the steps
below:
- Download and launch the EV Connect app.
- Scan the QR code or type in the Station ID.
- Plug in your vehicle and tap ‘Charge Now’.
Payment Processing
Once payment is initiated, Boost Charger will display information on the
payment status. Selecting ‘Cancel’ will stop payment authorization and return
to the home screen. If the payment authorization fails, the message “Error
Auth Failed. Please try again” will appear. Select the desired port, then
insert your payment or tap your RFID card to try again.
Payment Authorization
When the payment authorization is successful a screen with, “Authorization
success”, will appear, then the screen will instruct you to plug in the
vehicle to initiate charging.
CONNECT TO THE EV
Plug in Vehicle Notification
The screen will display which connector had been selected from the home
screen. Plug in the selected connector to the vehicle. If the wrong connector
was selected, tap ‘Cancel’ to return to the home screen and begin the process
again by selecting the correct connector.
Preparing to Charge
The Charging Start Up screen should say “Please Wait! Charging Session
Starting Up” above a flashing lightning bolt.
Active Charging
Charging Screen
When charging is in progress, charging information will be displayed on the
side of the screen that corresponds with the active connector. Information
includes:
- Current charge: Vehicle battery charge in percentage.
- Time elapsed: Time elapsed since charging was initiated in minutes and seconds.
- Energy delivered: Energy delivered to the vehicle in kilowatt-hours (kWh).
- Current power: Power delivered to the vehicle in kilowatts (kW).
- Total cost: Cost is contingent on the rate information provided in the ‘Pricing Details’ button available on the home screen.
’Stop Charging’ button will end the charging session and allow safe disconnect
from the vehicle.
NOTE: Do not attempt to remove the connector from the vehicle before you
have selected the ‘Stop Charging’ button. See more details in section 3.6.
DUAL CHARGING
Boost Charger can charge up to two EVs at once. Follow the steps below for
instructions on how to connect and charge a second vehicle.
Select Connector not in Use
The connector not in use will display the message “Available for charging”.
Select the panel for the available charger to initiate the charging process.
STOP CHARGING
Stop Charging
Charging can be stopped at any time. Simply tap the ‘Stop Charging’ button on
the corresponding connector panel. Power will stop at this time and the
payment session will end.
Charging Stopped
A charging stopped confirmation screen will appear the end of the charging
session. It is now safe to remove the connector from the vehicle. Tapping the
‘Exit’ button will return to the home screen.
Driver Support
If a user experiences any issues with using the Boost Charger, please contact
EV Connect at (866) 816-PLUG.
Boost Charger Maintenance
Maintenance Overview
The FreeWire Boost Charger is designed for minimal maintenance over its
lifetime. The network connection monitors the health of the system as well as
any error codes or faults. An alert is sent when corrective maintenance or
service might be required.
The Boost Charger Warranty includes preventative maintenance for the duration
of the selected warranty. While the Boost Charger is under warranty, FreeWire
Technologies, or a FreeWire approved contractor, will perform annual
preventative maintenance. If additional maintenance is required, please
contact EV Connect to arrange for the required work to be completed.
Only qualified technicians or FreeWire approved personnel can perform service
and/or maintenance on the Boost Charger. Work performed by unqualified
personnel can/will void the warranty on the Boost Charger.
For customer support or to schedule service and/or maintenance on the Boost
Charger, please contact EV Connect support at
888-780-0062.
Site Operator’s Responsibilities
The items below outline the responsibilities of the site or facility manager
when it comes to general site maintenance.
- In the event of smoke or fire, immediately call 9-1-1 to reach the fire department and refer to the Fire Department Tip Sheet.
- In case of emergency, the Boost Charger can be disabled by depressing the red emergency stop button located on the front of the unit or via a remote e-stop on site.
- If the emergency stop button on the front of the unit is accidentally engaged, pull out the button and the unit will automatically reboot.
- Make sure that the base and vents of the Boost Charger are clear of any blockage, debris, and snow.
- Keep the area free of any standing water or blocked drainage systems/sewers.
- Check to ensure that the charge cables are returned to their holsters to prevent damage from vehicles.
- Once a month, verify that the charging cables are free from any signs of wear or damage. If a cable appears damaged, please contact the EV Connect Site Host Support for a service visit.
- Check each station daily for vandalism or damage. If the station has been damaged, please contact the EV Connect Site Host Support to perform service or to replace parts.
CAUTION: Do not pressure wash the Boost Charger. High pressure water spray could cause damage to the system. Use a damp cloth to clean the Boost Charger.
Preventative Maintenance
Preventative maintenance is included in the Boost Charger warranty. FreeWire
Technologies or FreeWire approved personnel should perform all service checks
as defined below.
DANGER: RISK OF ELECTRIC SHOCK.
No user serviceable parts inside. Only authorized personnel may service this
equipment. To reduce the possibility of injury, turn main disconnect switch
“OFF” and padlock before servicing equipment.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF
LIFE.
Preventative Maintenance, Years 1-4
- Diagnostics / Inspection
- Input air filter replacement.
- Top-off radiator fluid.
Preventative Maintenance, Year 5
- Diagnostics / Inspection
- Input air filter replacement.
- Cooling pump, 1/3 HP, 120/240 VAC replacement.
- Battery, lithium, 25.6 V (low voltage) replacement.
Boost Charger Specifications
System
Max Output Power
| CHAdeMO: 100 kW
CCS: 120 kW
Combined: charge two vehicles up to 60 kW each
---|---
Max Output Current| CHAdeMO: 200 A
CCS: 300 A
Dimensions| 40 in x 43 in x 96 in
Weight| 3,800 lbs
Output Voltage, Charging| 200 VDC – 500 VDC
Electrical Input
Input Rating| 240 (+/- 10%) VAC, split-phase, 4-Wire, 120 A, 60 Hz
208 (+/- 10%) VAC 3-phase, WYE, 5-Wire, 80 A 60 Hz
---|---
Wiring| For 240 V – 2 conductors (L1, L2) Ground
For 208 V – 4 conductors (L1, L2, L3, Neutral) Ground
Required Service Panel Breaker| 150 A 240 V
100 A 208 V
Interfaces
| Supported Connector Types | CCS1 (SAE J1772™ Combo) CHAdeMO |
|---|---|
| Charge Cable Length | 140 in |
| User Interaction Display | Full-color 24-inch LCD display for driver |
interaction
Authentication| RFID: ISO 15693, ISO 14443, NFC
Safety and Compliance
Safety Compliance| U.S.: complies with UL 2202, UL 2231-1, UL 2231-2, UL 991,
UL 1973 (battery pack)
---|---
EMC Compliance| U.S.: FCC part 15 Class A
Safety: Electric Vehicle
- See the EV supplier’s guide for proper care of the EV and follow directions carefully. Failure to follow EV care instructions can results in EV explosion and property damage, severe injury, or death during charging.
- Do not disconnect charger connector while the EV is charging.
Environmental Requirements
| Location | Outdoor |
|---|---|
| Operating Temperature | -20° C to 55° C (-4° F to 131° F) |
| Storage Temperature | -20° C to 55° C (-4° F to 131° F) |
| Operating Humidity | Up to 95% at 55° C (131° F) non-condensing |
| Enclosure Rating | IP54 |
Any additional questions please contact:
415-484-9590
support@freewiretech.com
1933 Davis St. Suite 301A
San Leandro, CA 94577
Boost Charger Operating and Maintenance Manual v1.0. 8.28.2020
Part Number 770-00005-01