The URL can be used to link to this page

Home My WebLink About3600 W McFadden Ave-EV Chargers - PlanGENERAL CONSTRUCTION NOTES ELECTRICAL NOTES GENERAL SITE NOTES GENERAL NOTES GN-1 SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY SHEET 2 OF 10 FOR THE PURPOSE OF CONSTRUCTION DRAWINGS, THE FOLLOWING DEFINITIONS SHALL APPLY OWNER: ELECTRIFY AMERICA 1. ALL SITE WORK SHALL BE COMPLETED AS INDICATED ON THE DRAWINGS. 2. THE GENERAL CONTRACTOR SHALL VISIT THE SITE AND SHALL FAMILIARIZE THEMSELVES WITH ALL CONDITIONS AFFECTING THE PROPOSED WORK AND SHALL MAKE PROVISIONS. GENERAL CONTRACTOR SHALL BE RESPONSIBLE FOR FAMILIARIZING THEMSELVES WITH ALL CONTRACT DOCUMENTS, FIELD CONDITIONS, DIMENSIONS, AND CONFIRMING THAT THE WORK MAY BE ACCOMPLISHED AS SHOWN PRIOR TO PROCEEDING WITH CONSTRUCTION. ANY DISCREPANCIES SHALL BE BROUGHT TO THE ATTENTION OF THE ENGINEER PRIOR TO THE COMMENCEMENT OF WORK. 3. ALL MATERIALS FURNISHED AND INSTALLED SHALL BE IN STRICT ACCORDANCE WITH ALL APPLICABLE CODES, REGULATIONS, AND ORDINANCES. GENERAL CONTRACTOR SHALL ISSUE ALL APPROPRIATE NOTICES AND COMPLY WITH ALL LAWS, ORDINANCES, RULES, REGULATIONS, AND LAWFUL ORDERS OF ANY PUBLIC AUTHORITY REGARDING THE PERFORMANCE OF WORK. 4. ALL WORK CARRIED OUT SHALL COMPLY WITH ALL APPLICABLE MUNICIPAL AND UTILITY COMPANY SPECIFICATIONS AND LOCAL JURISDICTIONAL CODES, ORDINANCES, AND APPLICABLE REGULATIONS. 5.UNLESS NOTED OTHERWISE, THE WORK SHALL INCLUDE FURNISHING MATERIALS, EQUIPMENT, APPURTENANCES, AND LABOR NECESSARY TO COMPLETE ALL INSTALLATIONS AS INDICATED ON THE DRAWINGS. 6. PLANS ARE NOT TO BE SCALED. THESE PLANS ARE INTENDED TO BE A DIAGRAMMATIC OUTLINE ONLY UNLESS OTHERWISE NOTED. DIMENSIONS SHOWN ARE TO FINISH SURFACES UNLESS OTHERWISE NOTED. SPACING BETWEEN EQUIPMENT IS THE MINIMUM REQUIRED CLEARANCE. THEREFORE, IT IS CRITICAL TO FIELD VERIFY DIMENSIONS, SHOULD THERE BE ANY QUESTIONS REGARDING THE CONTRACT DOCUMENTS, THE CONTRACTOR SHALL BE RESPONSIBLE FOR OBTAINING A CLARIFICATION FROM THE ENGINEER PRIOR TO PROCEEDING WITH THE WORK. DETAILS ARE INTENDED TO SHOW DESIGN INTENT. MODIFICATIONS MAY BE REQUIRED TO SUIT JOB DIMENSIONS OR CONDITIONS AND SUCH MODIFICATIONS SHALL BE INCLUDED AS PART OF WORK AND PREPARED BY THE ENGINEER PRIOR TO PROCEEDING WITH WORK. 7. THE CONTRACTOR SHALL INSTALL ALL EQUIPMENT AND MATERIALS IN ACCORDANCE WITH MANUFACTURER'S RECOMMENDATIONS UNLESS SPECIFICALLY STATED OTHERWISE. 8. IF THE SPECIFIED EQUIPMENT CANNOT BE INSTALLED AS SHOWN ON THESE DRAWINGS, THE CONTRACTOR SHALL PROPOSE AN ALTERNATIVE INSTALLATION SPACE FOR APPROVAL BY THE ENGINEER PRIOR TO PROCEEDING. 9. THE GENERAL CONTRACTOR SHALL BE RESPONSIBLE FOR THE SAFETY OF WORK AREA, ADJACENT AREAS AND BUILDING OCCUPANTS THAT ARE LIKELY TO BE AFFECTED BY THE WORK UNDER THIS CONTRACT. WORK SHALL CONFORM TO ALL OSHA REQUIREMENTS AND THE LOCAL JURISDICTION. 10. THE GENERAL CONTRACTOR SHALL COORDINATE WORK AND SCHEDULE WORK ACTIVITIES WITH OTHER DISCIPLINES. 11. CONSTRUCTION SHALL BE DONE IN A WORKMANLIKE MANNER BY COMPETENT EXPERIENCED WORKMAN IN ACCORDANCE WITH APPLICABLE CODES AND THE BEST ACCEPTED PRACTICE. 12. WORK PREVIOUSLY COMPLETED IS REPRESENTED BY LIGHT SHADED LINES AND NOTES. THE SCOPE OF WORK FOR THIS PROJECT IS REPRESENTED BY DARK SHADED LINES AND NOTES. CONTRACTOR SHALL NOTIFY THE GENERAL CONTRACTOR OF ANY EXISTING CONDITIONS THAT DEVIATE FROM THE DRAWINGS PRIOR TO BEGINNING CONSTRUCTION. 13. THE CONTRACTOR SHALL PROVIDE WRITTEN NOTICE TO THE CONSTRUCTION MANAGER 48 HOURS PRIOR TO COMMENCEMENT OF WORK. 14. THE CONTRACTOR SHALL PROTECT EXISTING IMPROVEMENTS, PAVEMENTS, CURBS, LANDSCAPING AND STRUCTURES. ANY DAMAGED PART SHALL BE REPAIRED AT CONTRACTOR'S EXPENSE TO THE SATISFACTION OF THE OWNER. 15. THE CONTRACTOR SHALL CONTACT UTILITY LOCATING SERVICES PRIOR TO THE START OF CONSTRUCTION. 16. THE GENERAL CONTRACTOR SHALL COORDINATE AND MAINTAIN ACCESS FOR ALL TRADES AND CONTRACTORS TO THE SITE AND/OR BUILDING. 17. THE GENERAL CONTRACTOR SHALL BE RESPONSIBLE FOR SECURITY OF THE SITE FOR THE DURATION OF CONSTRUCTION UNTIL JOB COMPLETION. 18. THE GENERAL CONTRACTOR SHALL MAINTAIN IN GOOD CONDITION ONE COMPLETE SET OF PLANS WITH ALL REVISIONS, ADDENDA, AND CHANGE ORDERS ON THE PREMISES AT ALL TIMES. 19. THE CONTRACTOR SHALL PROVIDE PORTABLE FIRE EXTINGUISHERS WITH A RATING OF NOT LESS THAN 2-A:10-B:C AND SHALL BE WITHIN 25 FEET OF TRAVEL DISTANCE TO ALL PORTIONS OF WHERE THE WORK IS BEING COMPLETED DURING CONSTRUCTION. 20. ALL EXISTING ACTIVE SEWER, WATER, GAS, ELECTRIC, AND OTHER UTILITIES SHALL BE PROTECTED AT ALL TIMES, AND WHERE REQUIRED FOR THE PROPER EXECUTION OF THE WORK, SHALL BE RELOCATED AS DIRECTED BY THE ENGINEER. EXTREME CAUTION SHOULD BE USED BY THE CONTRACTOR WHEN EXCAVATING OR DRILLING PIERS AROUND OR NEAR UTILITIES. 21.THE CONTRACTOR SHALL PROVIDE SAFETY TRAINING FOR THE WORKING CREW. THIS SHALL INCLUDE BUT NOT BE LIMITED TO A) FALL PROTECTION, B) CONFINED SPACE, C) ELECTRICAL SAFETY, AND D) TRENCHING & EXCAVATION. 22. ALL EXISTING INACTIVE SEWER, WATER, GAS, ELECTRIC, AND OTHER UTILITIES, WHICH INTERFERE WITH THE EXECUTION OF THE WORK, SHALL BE REMOVED, CAPPED, PLUGGED OR OTHERWISE DISCONNECTED AT POINTS WHICH WILL NOT INTERFERE WITH THE EXECUTION OF THE WORK, AS DIRECTED BY THE ENGINEER, AND SUBJECT TO THE APPROVAL OF THE OWNER AND/OR LOCAL UTILITIES. 23. THE AREAS OF THE OWNER'S PROPERTY DISTURBED BY THE WORK AND NOT COVERED BY THE EQUIPMENT OR DRIVEWAY, SHALL BE GRADED TO A UNIFORM SLOPE, AND STABILIZED TO PREVENT EROSION. 24. CONTRACTOR SHALL MINIMIZE DISTURBANCE TO THE EXISTING SITE DURING CONSTRUCTION. EROSION CONTROL MEASURES, IF REQUIRED DURING CONSTRUCTION, SHALL BE IN CONFORMANCE WITH THE FEDERAL AND LOCAL JURISDICTION FOR EROSION AND SEDIMENT CONTROL. 25. NO FILL OR EMBANKMENT MATERIAL SHALL BE PLACED ON FROZEN GROUND. FROZEN MATERIALS, SNOW OR ICE SHALL NOT BE PLACED IN ANY FILL OR EMBANKMENT. 26. THE SUBGRADE SHALL BE BROUGHT TO A SMOOTH UNIFORM GRADE AND COMPACTED TO 95 PERCENT STANDARD PROCTOR DENSITY UNDER PAVEMENT AND STRUCTURES AND 80 PERCENT STANDARD PROCTOR DENSITY IN OPEN SPACE. ALL TRENCHES IN PUBLIC RIGHT OF WAY SHALL BE BACKFILLED WITH FLOWABLE FILL OR OTHER MATERIAL PRE-APPROVED BY THE LOCAL JURISDICTION. 27. ALL NECESSARY RUBBISH, STUMPS, DEBRIS, STICKS, STONES, AND OTHER REFUSE SHALL BE REMOVED FROM THE SITE AND DISPOSED OF IN A LAWFUL MANNER. 28. ALL BROCHURES, OPERATING AND MAINTENANCE MANUALS, CATALOGS, SHOP DRAWINGS, AND OTHER DOCUMENTS SHALL BE TURNED OVER TO THE GENERAL CONTRACTOR AT COMPLETION OF CONSTRUCTION AND PRIOR TO PAYMENT. 29. THE CONTRACTOR SHALL SUBMIT A COMPLETE SET OF AS-BUILT REDLINES TO THE GENERAL CONTRACTOR UPON COMPLETION OF PROJECT AND PRIOR TO FINAL PAYMENT. 30. THE CONTRACTOR SHALL LEAVE PREMISES IN A CLEAN CONDITION. 31. THE PROPOSED FACILITY WILL BE UNMANNED AND DOES NOT REQUIRE POTABLE WATER OR SEWER SERVICE, AND IS NOT FOR HUMAN HABITATION (NO HANDICAP ACCESS REQUIRED). 32. NO OUTDOOR STORAGE OR SOLID WASTE CONTAINERS ARE PROPOSED. 33. CONTRACTORS SHALL BE RESPONSIBLE FOR OBTAINING ALL PERMITS AND INSPECTIONS REQUIRED FOR CONSTRUCTION. IF CONTRACTOR CANNOT OBTAIN A PERMIT, THEY MUST NOTIFY THE GENERAL CONTRACTOR IMMEDIATELY. 34. THE CONTRACTOR SHALL REMOVE ALL TRASH AND DEBRIS FROM THE SITE ON A DAILY BASIS. 35. INFORMATION SHOWN ON THESE DRAWINGS WAS OBTAINED FROM SITE VISITS AND/OR DRAWINGS PROVIDED BY THE SITE OWNER. CONTRACTORS SHALL NOTIFY THE ENGINEER OF ANY DISCREPANCIES PRIOR TO ORDERING MATERIAL OR PROCEEDING WITH CONSTRUCTION. 1. THE ELECTRICAL CONTRACTOR SHALL SUPPLY AND INSTALL ANY/ALL ELECTRICAL WORK INDICATED. ANY/ALL CONSTRUCTION SHALL BE IN ACCORDANCE WITH DRAWINGS AND ANY/ALL APPLICABLE SPECIFICATIONS. IF ANY PROBLEMS ARE ENCOUNTERED BY COMPLYING WITH THESE REQUIREMENTS, CONTRACTOR SHALL NOTIFY 'CONSTRUCTION MANAGER' AS SOON AS POSSIBLE, AFTER THE DISCOVERY OF THE PROBLEMS, AND SHALL NOT PROCEED WITH THAT PORTION OF WORK, UNTIL THE 'CONSTRUCTION MANAGER' HAS DIRECTED THE CORRECTIVE ACTIONS TO BE TAKEN. 2. THE ELECTRICAL CONTRACTOR SHALL VISIT THE JOB SITE AND FAMILIARIZE THEMSELVES WITH ANY/ALL CONDITIONS AFFECTING ELECTRICAL AND COMMUNICATION INSTALLATION AND MAKE PROVISIONS AS TO THE COST THEREOF. THE CONDITION OF EXISTING ELECTRICAL EQUIP., LIGHT FIXTURES, ETC., THAT ARE PART OF THE FINAL SYSTEM, SHALL BE VERIFIED BY THE CONTRACTOR, PRIOR TO THE SUBMITTAL OF HIS BID. FAILURE TO COMPLY WITH THIS PARAGRAPH WILL IN NO WAY RELIEVE CONTRACTOR OF PERFORMING ALL WORK NECESSARY FOR A COMPLETE AND WORKING SYSTEM. 3. ALL WORK SHALL BE PERFORMED IN ACCORDANCE WITH THE LATEST EDITION OF THE NEC AND ALL CODES AND LOCAL ORDINANCES OF THE LOCAL POWER COMPANIES HAVING JURISDICTION AND SHALL INCLUDE BUT NOT BE LIMITED TO: A. UL - UNDERWRITERS LABORATORIES B. NEC - NATIONAL ELECTRICAL CODE C. NEMA - NATIONAL ELECTRICAL MANUFACTURERS ASSOC. D. OSHA - OCCUPATIONAL SAFETY AND HEALTH ACT E. SBC - STANDARD BUILDING CODE F. NFPA - NATIONAL FIRE PROTECTION ASSOCIATION 4. DO NOT SCALE ELECTRICAL DRAWINGS, REFER TO SITE PLANS AND ELEVATIONS FOR EXACT LOCATIONS OF ALL EQUIPMENT, BUT CONFIRM WITH 'CONSTRUCTION MANAGER' ANY SIZES AND LOCATIONS WHEN NEEDED. 5. EXISTING SERVICES: THE CONTRACTOR SHALL NOT INTERRUPT EXISTING SERVICES WITHOUT WRITTEN PERMISSION OF THE OWNER. 6. THE CONTRACTOR SHALL PAY FOR ANY/ALL PERMITS, FEES, INSPECTIONS AND TESTING. THE CONTRACTOR IS TO OBTAIN PERMITS AND APPROVED SUBMITTALS PRIOR TO THE WORK BEGINNING OR ORDERING THE EQUIPMENT. 7. THE TERM "PROVIDE" USED IN CONSTRUCTION DOCUMENTS AND SPECIFICATIONS, INDICATES THAT THE CONTRACTOR SHALL FURNISH AND INSTALL. 8. THE CONTRACTOR SHALL CONFIRM WITH LOCAL UTILITY COMPANY ANY/ALL REQUIREMENTS SUCH AS THE: LUG SIZE RESTRICTIONS, CONDUIT ENTRY, SIZE OF TRANSFORMERS, SCHEDULED DOWNTIME FOR THE OWNERS' CONFIRMATION, ETC. ANY/ALL CONFLICTS SHALL BE BROUGHT TO THE ATTENTION OF THE CONSTRUCTION MANAGER, PRIOR TO BEGINNING ANY WORK. 9.CONDUCTORS: CONTRACTOR SHALL USE 98% CONDUCTIVITY COPPER OR ALUMINUM WITH TYPE (THWN-2) INSULATION, 600 VOLT, COLOR CODED UNLESS SPECIFIED DIFFERENTLY ON DRAWINGS. 10. ALL (THWN-2) AND (XHHW) WIRING INSTALLATIONS TO FOLLOW MANUFACTURER'S INSTRUCTIONS AND RECOMMENDATIONS. 11. OUTLET BOXES SHALL BE PRESSED STEEL IN DRY LOCATIONS, CAST ALLOY WITH THREADED HUBS IN WET/DAMP LOCATIONS AND SPECIAL ENCLOSURES FOR OTHER CLASSIFIED AREAS. 12. IT IS NOT THE INTENT OF THESE PLANS TO SHOW EVERY MINOR DETAIL OF THE CONSTRUCTION. CONTRACTOR IS EXPECTED TO FURNISH AND INSTALL ALL ITEMS FOR A COMPLETE ELECTRICAL SYSTEM AND PROVIDE ALL REQUIREMENTS FOR THE EQUIPMENT TO BE PLACED IN PROPER WORKING ORDER. CONTRACTOR IS TO PROVIDE ALL ELECTRICAL EQUIPMENT UNLESS OTHERWISE DIRECTED. 13. ALL WORK SHALL BE PERFORMED BY A LICENSED ELECTRICAL CONTRACTOR IN A FIRST CLASS, WORKMANLIKE MANNER. THE COMPLETED SYSTEM SHALL BE FULLY OPERATIONAL AND SUBJECT TO REGULATORY INSPECTION AND APPROVAL BY CONSTRUCTION MANAGER. 14. ALL WORK SHALL BE COORDINATED WITH OTHER TRADES TO AVOID INTERFERENCE WITH THE PROGRESS OF CONSTRUCTION. 15. CONTRACTOR SHALL GUARANTEE ANY/ALL MATERIALS AND WORK FREE FROM DEFECTS FOR A PERIOD OF NOT LESS THAN ONE YEAR FROM DATE OF ACCEPTANCE. 16. THE CORRECTION OF ANY DEFECTS SHALL BE COMPLETED WITHOUT ANY ADDITIONAL CHARGE AND SHALL INCLUDE THE REPLACEMENT OR THE REPAIR OF ANY OTHER PHASE OF THE INSTALLATION, WHICH MAY HAVE BEEN DAMAGED THEREIN. 17. ADEQUATE AND REQUIRED LIABILITY INSURANCE SHALL BE PROVIDED FOR PROTECTION AGAINST PUBLIC LOSS AND ANY/ALL PROPERTY DAMAGE FOR THE DURATION OF WORK. 18. PROVIDE AND INSTALL CONDUIT, CONDUCTORS, PULL WIRES, BOXES, COVER PLATES AND DEVICES FOR ALL OUTLETS AS INDICATED. 19. TRENCHING AND BACKFILL: THE CONTRACTOR SHALL PROVIDE FOR ALL UNDERGROUND INSTALLED CONDUIT AND/OR CABLES INCLUDING EXCAVATION AND BACKFILLING AND COMPACTION. REFER TO GENERAL SITE WORK NOTES. 20. MATERIALS, PRODUCTS AND EQUIPMENT, INCLUDING ALL COMPONENTS THEREOF, SHALL BE NEW AND SHALL APPEAR ON THE LIST OF U.L. APPROVED ITEMS AND SHALL MEET OR EXCEED THE REQUIREMENTS OF THE NEC, NEMA AND IEEE. 21. CONTRACTOR SHALL SUBMIT SHOP DRAWINGS OR MANUFACTURES CATALOG INFORMATION OF ANY/ALL LIGHTING FIXTURES, SWITCHES AND ALL OTHER ELECTRICAL ITEMS FOR APPROVAL BY THE CONSTRUCTION MANAGER PRIOR TO INSTALLATION. 22. ANY CUTTING OR PATCHING DEEMED NECESSARY FOR ELECTRICAL WORK IS THE ELECTRICAL CONTRACTORS RESPONSIBILITY AND SHALL BE INCLUDED IN THE COST FOR WORK AND PERFORMED TO THE SATISFACTION OF THE 'CONSTRUCTION MANAGER' UPON FINAL ACCEPTANCE. 23. THE ELECTRICAL CONTRACTOR SHALL LABEL ALL PANELS WITH ONLY TYPEWRITTEN DIRECTORIES. 24. IF REQUIRED, DISCONNECT SWITCHES SHALL BE H.P. RATED HEAVY-DUTY, QUICK-MAKE AND QUICK-BREAK ENCLOSURES, AS REQUIRED BY EXPOSURE TYPE. 25. ALL CONNECTIONS EXCEPT THE EV CHARGE CABLE TERMINATION IN THE CHARGE POST SHALL BE MADE WITH A PROTECTIVE COATING OF AN ANTI-OXIDE COMPOUND SUCH AS "NOALOX" BY IDEAL INDUSTRIAL INC., COAT ALL WIRE SURFACES BEFORE CONNECTING. EXPOSED ALUMINUM & COPPER SURFACES, INCLUDING GROUND BARS, SHALL BE TREATED - NO SUBSTITUTIONS. 26. ALL EXTERIOR AND INTERIOR ABOVE GROUND CONDUIT SHALL BE RIGID UNLESS SPECIFIED OTHERWISE. ALL BURIED CONDUITS SHALL BE SCH 40 PVC UNLESS SPECIFIED OTHERWISE. 27. RACEWAYS: CONDUIT SHALL BE SCHEDULE 40 PVC, MEETING OR EXCEEDING NEMA TC2 - 1990. THE CONTRACTOR SHALL PLUG AND CAP EACH END OF SPARE AND EMPTY CONDUITS AND PROVIDE TWO SEPARATE PULL STRINGS - 200 LBS TEST POLYETHYLENE CORD. ALL CONDUIT BENDS SHALL BE A MINIMUM OF 3 FT. RADIUS. RGS CONDUITS WHEN SPECIFIED, SHALL MEET UL-6 FOR GALVANIZED STEEL. ALL FITTINGS SHALL BE SUITABLE FOR USE WITH THREADED RIGID CONDUIT. COAT ALL THREADS WITH 'BRITE ZINC' OR 'GOLD GALV'. 28. SUPPORT OF ALL ELECTRICAL WORK SHALL BE AS REQUIRED BY NEC. 29. CONNECTORS FOR POWER CONDUCTORS: CONTRACTOR SHALL USE PRESSURE TYPE INSULATED TWIST-ON CONNECTORS FOR NO. 10 AWG AND SMALLER. USE SOLDERLESS MECHANICAL TERMINAL LUGS FOR NO. 8 AWG AND LARGER. 30. THE CONTRACTOR SHALL PLACE WARNING TAPE AT A DEPTH OF 12" BELOW GROUND AND DIRECTLY ABOVE ELECTRICAL SERVICE CONDUITS. CAUTION TAPE TO READ "CAUTION BURIED ELECTRIC". 31. WHEN DIRECTIONAL BORING IS REQUIRED, CONTRACTOR SHALL INSTALL A LOOSE TONING WIRE WITHIN INSTALLED CONDUIT TO ALLOW FOR IDENTIFICATION OF UNDERGROUND CONDUITS. 32. ALL BOLTS SHALL BE STAINLESS STEEL. 33. ALL MATERIALS AND EQUIPMENT SUPPLIED AND INSTALLED BY THE CONTRACTOR SHOULD BE NEW AND UNUSED. PART 1 - GENERAL CLEARING, GRUBBING, STRIPPING, EROSION CONTROL, SURVEY, LAYOUT, SUBGRADE PREPARATION AND FINISH GRADING AS REQUIRED TO COMPLETE THE PROPOSED WORK SHOWN IN THESE PLANS. 1. REFERENCES: A. LOCAL DOT TRANSPORTATION STANDARD SPECIFICATIONS FOR HIGHWAY CONSTRUCTION (CURRENT EDITION) B. ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS). C. OSHA (OCCUPATION SAFETY AND HEALTH ADMINISTRATION). 2. INSPECTION AND TESTING: A. GENERAL CONTRACTOR SHALL PERFORM ALL WORK IN CONFORMANCE WITH THE PLANS AND SPECIFICATIONS. PERFORM INSPECTIONS BEFORE CONCEALING WORK WITH FOLLOW-ON ACTIVITIES (BACKFILL, CONCRETE POUR, ETC). 3. SITE MAINTENANCE AND PROTECTION: A. PROVIDE ALL NECESSARY JOB SITE MAINTENANCE FROM COMMENCEMENT OF WORK UNTIL COMPLETION OF THE CONTRACT. B. AVOID DAMAGE TO THE SITE AND TO EXISTING FACILITIES, STRUCTURES, TREES, AND SHRUBS DESIGNATED TO REMAIN. TAKE PROTECTIVE MEASURES TO PREVENT EXISTING FACILITIES THAT ARE NOT DESIGNATED FOR REMOVAL FROM BEING DAMAGED BY THE WORK. C. KEEP SITE FREE OF ALL PONDING WATER. D. PROVIDE EROSION CONTROL MEASURES IN ACCORDANCE WITH STATE DOT, LOCAL PERMITTING AGENCY AND EPA REQUIREMENTS. E. PROVIDE AND MAINTAIN ALL TEMPORARY FENCING, BARRICADES, WARNING SIGNALS AND SIMILAR DEVICES NECESSARY TO PROTECT AGAINST THEFT FROM PROPERTY DURING THE ENTIRE PERIOD OF CONSTRUCTION. REMOVE ALL SUCH DEVICES UPON COMPLETION OF THE WORK. F. EXISTING UTILITIES: DO NOT INTERRUPT EXISTING UTILITIES SERVING FACILITIES OCCUPIED BY THE OWNER OR OTHERS, EXCEPT WHEN PERMITTED IN WRITING BY THE CONSTRUCTION MANAGER AND THEN ONLY AFTER ACCEPTABLE TEMPORARY UTILITY SERVICES HAVE BEEN PROVIDED. G. PROVIDE A MINIMUM 48-HOUR NOTICE TO THE CONSTRUCTION MANAGER AND RECEIVE WRITTEN NOTICE TO PROCEED BEFORE INTERRUPTING ANY UTILITY SERVICE. H. SOD PLANTED IN THE FALL MUST ESTABLISH ITS ROOTS BEFORE THE FIRST WINTER FROST. DETERMINE WHEN THE FIRST FROST USUALLY OCCURS, AND PLANT THE SOD NO LATER THAN ONE MONTH BEFORE THE FIRST FROST. IF THE CONSTRUCTION IS FINISHED LATER THAN ONE MONTH BEFORE THE FIRST FROST, USE STRAW UNTIL SOD CAN BE INSTALLED. PART 2 - PRODUCTS 1. SUITABLE MATERIAL – SUITABLE MATERIAL ARE TO BE USED FOR GRADING AND BACKFILL. SUITABLE MATERIALS ARE ON SITE SOILS REMOVED FROM EXCAVATIONS THAT EXCLUDE FROZEN SOIL, ROOTS OR ORGANIC MATERIAL, DEBRIS, TRASH, REFUSE, OR PARTICLES SIZE GREATER THAN 3-INCH. SUITABLE SOILS HAVE MOISTURE CONTENTS THAT ALLOW THEM TO BE COMPACTED TO THE SAME DENSITY AS THE NATIVE SOILS. 2. UNSUITABLE MATERIAL – SOILS THAT ARE FROZEN, CONTAIN ROOTS OR ORGANIC MATERIAL, DEBRIS, TRASH, REFUSE, OR PARTICLES SIZES GREATER THAN 3-INCH. SOILS THAT ARE TOO WET OR TOO DRY TO BE COMPACTED TO THE SAME DENSITY AS THE NATIVE SOILS ARE UNSUITABLE. 3. GRANULAR BACKFILL – SHALL MEET THE FOLLOWING GRADATION 4. GRANULAR BEDDING – WELL-GRADED SAND MEETING THE GRADATION REQUIREMENT OF ASTM C 33 FINE AGGREGATE. 5. CONTROLLED LOW STRENGTH MATERIAL (CLSM)– A SELF LEVELING AND SELF COMPACTING CEMENTITIOUS MATERIAL COMPOSED OF SAND, COARSE AGGREGATE, CEMENT, FLY ASH, WATER AND ADMIXTURES. CLSM SHALL BE EXCAVATABLE AND SHALL HAVE A DESIGNED UNCONFINED COMPRESSIVE STRENGTH OF BETWEEN 50 TO 100 PSI. 6. BACKFILL – PRODUCTS MEETING THE REQUIREMENTS OF SUITABLE MATERIAL, GRANULAR BEDDING, GRANULAR BACKFILL OR CLSM. 7. TOPSOIL – SOIL WITH AN ORGANIC CONTENT SUFFICIENT TO ALLOW VEGETATIVE GROWTH. SIEVE SIZE TOTAL PERCENT PASSING 1 1/2 INCH (37.5 MM)100 NO. 4 (4.75 MM)30 TO 60 NO 200 (0.075 MM)3 TO 15 GROUNDING NOTES GENERAL SITE NOTES CONT.GENERAL SITE NOTES CONT. ANCHORAGE INSTALLATION NOTES STRUCTURAL STEEL NOTES FIBER OPTIC NOTES GENERAL NOTES GN-2 SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY SHEET 3 OF 10 PART 3 - EXECUTION 1. GENERAL: A. BEFORE STARTING GENERAL SITE PREPARATION ACTIVITIES, INSTALL EROSION AND SEDIMENT CONTROL MEASURES. THE WORK AREA SHALL BE CONSTRUCTED AND MAINTAINED IN SUCH CONDITION THAT IN THE EVENT OF RAIN THE SITE WILL BE DRAINED AT ALL TIMES. B. BEFORE ALL SURVEY, LAYOUT, STAKING, AND MARKING, ESTABLISH AND MAINTAIN ALL LINES, GRADES, ELEVATIONS AND BENCHMARKS NEEDED FOR EXECUTION OF THE WORK. CONDUCT UTILITY LOCATE IN ACCORDANCE WITH THE ONE-CALL NOTIFICATION C. CLEAR AND GRUB THE AREA WITHIN THE LIMITS OF THE SITE. REMOVE TREES, BRUSH, STUMPS, RUBBISH AND OTHER DEBRIS AND VEGETATION RESTING ON OR PROTRUDING THROUGH THE SURFACE OF THE SITE AREA TO BE CLEARED. D. REMOVE THE FOLLOWING MATERIALS TO A DEPTH OF NO LESS THAN 12 INCHES BELOW THE ORIGINAL GROUND SURFACE: ROOTS, STUMPS, AND OTHER DEBRIS, BRUSH, AND REFUSE EMBEDDED IN OR PROTRUDING THROUGH THE GROUND SURFACE, RAKE, DISK OR PLOW THE AREA TO A DEPTH OF NO LESS THAN 6 INCHES, AND REMOVE TO A DEPTH OF 12 INCHES ALL ROOTS AND OTHER DEBRIS THEREBY EXPOSED. E. REMOVE TOPSOIL MATERIAL COMPLETELY FROM THE SURFACE UNTIL THE SOIL NO LONGER MEETS THE DEFINITION OF TOPSOIL. AVOID MIXING TOPSOIL WITH SUBSOIL OR OTHER UNDESIRABLE MATERIALS. SUFFICIENT TOPSOIL MAY BE STOCKPILED ON SITE FOR USE DURING FINAL SITE GRADING. F. EXCEPT WHERE EXCAVATION TO GREATER DEPTH IS INDICATED, FILL DEPRESSIONS RESULTING FROM CLEARING, GRUBBING AND DEMOLITION WORK COMPLETELY WITH SUITABLE MATERIAL. G. REMOVE FROM THE SITE AND DISPOSE IN AN AUTHORIZED LANDFILL ALL DEBRIS RESULTING FROM CLEARING AND GRUBBING OPERATIONS. BURNING WILL NOT BE PERMITTED. H. PRIOR TO EXCAVATING, THOROUGHLY EXAMINE THE AREA TO BE EXCAVATED AND/OR TRENCHED TO VERIFY THE LOCATIONS OF FEATURES INDICATED ON THE DRAWINGS AND TO ASCERTAIN THE EXISTENCE AND LOCATION OF ANY STRUCTURE, UNDERGROUND STRUCTURE, OR OTHER ITEM NOT SHOWN THAT MIGHT INTERFERE WITH THE PROPOSED CONSTRUCTION. NOTIFY THE CONSTRUCTION MANAGER OF ANY OBSTRUCTIONS THAT WILL PREVENT ACCOMPLISHMENT OF THE WORK AS INDICATED ON THE DRAWINGS. I. SEPARATE AND STOCK PILE ALL EXCAVATED MATERIALS SUITABLE FOR BACKFILL. ALL EXCESS EXCAVATED AND UNSUITABLE MATERIALS SHALL BE DISPOSED OF OFF-SITE IN A LEGAL MANNER. J. DURING EXCAVATION, THE CONTRACTOR SHALL PROVIDE SHORING, SHEETING, AND BRACING AS REQUIRED TO PREVENT CAVING OR SLOUGHING OF EXCAVATION. 2. BACKFILL: A. AS SOON AS PRACTICAL, AFTER COMPLETING CONSTRUCTION OF THE RELATED STRUCTURE, INCLUDING EXPIRATION OF THE SPECIFIED MINIMUM CURING PERIOD FOR CAST-IN-PLACE CONCRETE, BACKFILL THE EXCAVATION WITH APPROVED MATERIAL TO RESTORE THE REQUIRED FINISHED GRADE. B. PRIOR TO PLACING BACKFILL AROUND STRUCTURES, ALL FORMS SHALL BE REMOVED AND THE EXCAVATION CLEANED OF ALL TRASH, DEBRIS, AND UNSUITABLE MATERIALS. C. DO NOT PLACE FROZEN MATERIAL IN AS BACKFILL. D. PLACE BACKFILL MATERIAL OR SELECT GRANULAR BACKFILL MATERIAL WHEN REQUIRED IN UNIFORM HORIZONTAL LAYERS OF NO GREATER THAN 8-INCHES LOOSE THICKNESS AND COMPACT TO THE SAME DENSITY AS NATIVE SOIL. WHERE HAND OPERATED COMPACTORS ARE USED, THE FILL MATERIAL SHALL BE PLACED IN LIFTS NOT TO EXCEED 4 INCHES IN LOOSE DEPTH AND COMPACTED. E. WHENEVER TESTING INDICATES THAT THE CONTRACTOR HAS NOT OBTAINED THE SPECIFIED DENSITY, THE SUCCEEDING LAYER SHALL NOT BE PLACED UNTIL THE REQUIREMENTS ARE MET UNLESS OTHERWISE AUTHORIZED BY THE CONSTRUCTION MANAGER. THE CONTRACTOR SHALL TAKE WHATEVER APPROPRIATE ACTION IS NECESSARY, SUCH AS DRYING, ADDING WATER, OR INCREASING THE COMPACTIVE EFFORT TO MEET THE COMPACTION REQUIREMENTS. 3. TRENCH EXCAVATION: A. UTILITY TRENCHES SHALL BE EXCAVATED TO THE LINES AND GRADES SHOWN ON THE DRAWINGS OR AS DIRECTED BY THE GENERAL CONTRACTOR. PROVIDE SHORING, SHEETING AND BRACING AS REQUIRED TO PREVENT CAVING OR SLOUGHING OF THE TRENCH WALLS. B. EXTEND THE TRENCH WIDTH A MINIMUM OF 6 INCHES BEYOND THE OUTSIDE EDGE OF THE OUTERMOST CONDUIT. C. WHEN SOFT YIELDING, OR OTHERWISE UNSTABLE SOIL CONDITIONS ARE ENCOUNTERED, EXCAVATE THE REQUIRED TRENCH TO A DEPTH OF NO LESS THAN 12 INCHES BELOW THE REQUIRED ELEVATION, THEN BACKFILL WITH 12" OF GRANULAR BEDDING MATERIAL. 4. TRENCH BACKFILL: A. PROVIDE GRANULAR BEDDING MATERIAL OR FLOWABLE FILL IN ACCORDANCE WITH THE DRAWINGS AND THE UTILITY REQUIREMENTS. B. NOTIFY THE GENERAL CONTRACTOR 24 HOURS IN ADVANCE OF BACKFILLING. C. CONDUCT UTILITY CHECK TESTS BEFORE BACKFILLING. BACKFILL AND COMPACT TRENCH BEFORE ACCEPTANCE TESTING. D. PLACE GRANULAR TRENCH BACKFILL UNIFORMLY ON BOTH SIDES OF THE CONDUITS IN 6-INCH UNCOMPACTED LIFTS UNTIL 12 INCHES OVER THE CONDUITS. SOLIDLY RAM AND TAMP BACKFILL INTO SPACE AROUND CONDUITS. E. PROTECT CONDUIT FROM LATERAL MOVEMENT, IMPACT DAMAGE, OR UNBALANCED LOADING. F. ABOVE THE CONDUIT EMBEDMENT ZONE, PLACE AND COMPACT SATISFACTORY BACKFILL MATERIAL IN 8-INCH MAXIMUM LOOSE THICKNESS LIFTS TO RESTORE THE REQUIRED FINISHED SURFACE GRADE. G. COMPACT FINAL TRENCH BACKFILL TO A DENSITY EQUAL TO OR GREATER THAN THAT OF THE EXISTING UNDISTURBED MATERIAL IMMEDIATELY ADJACENT TO THE TRENCH. 5. FINISH GRADING: A. PERFORM ALL GRADING TO PROVIDE POSITIVE DRAINAGE AWAY FROM STRUCTURES AND SMOOTH, EVEN SURFACE DRAINAGE OF THE ENTIRE AREA WITHIN THE LIMITS OF CONSTRUCTION. GRADING SHALL BE COMPATIBLE WITH ALL SURROUNDING TOPOGRAPHY AND STRUCTURES. B. UTILIZE SATISFACTORY FILL MATERIAL RESULTING FROM THE EXCAVATION WORK IN THE CONSTRUCTION OF FILLS, EMBANKMENTS AND FOR REPLACEMENT OF REMOVED UNSUITABLE MATERIALS. C. REPAIR ALL ACCESS ROADS AND SURROUNDING AREAS USED DURING THE COURSE OF THIS WORK TO THEIR ORIGINAL CONDITION. 6. ASPHALT PAVING ROAD: A. CONTRACTOR RESPONSIBLE FOR RE-STRIPING AND APPLYING SEALCOATING, UNLESS OTHERWISE NOTED. B. LOCAL DOT STANDARD SPECIFICATION, CURRENT EDITION. 7. STAGING: A. WORK / STAGING AREA TO BE CONFIRMED AT PRE-CONSTRUCTION SITE MEETING AND SURROUNDED BY TEMPORARY FENCE (SEE DETAIL BELOW) DURING CONSTRUCTION. B. POSSIBLE LOCATION FOR TEMPORARY DRIVE AISLE CLOSURE DURING CONSTRUCTION. C. CONTRACTOR TO PROVIDE TEMPORARY SIGNS TO DIRECT TRAFFIC FLOW. D. SHORT TERM FENCING TO BE PROVIDED OUTSIDE OF TEMPORARY FENCE FOR ANY OPEN TRENCHES LEFT OVER NIGHT OR UNATTENDED. E. TEMPORARY FENCE SHALL BE CLOSED AND LOCKED AT ALL TIMES. IF GATE MUST BE OPEN FOR MOVING EQUIPMENT OR MATERIALS, A SPOTTER SHALL BE PROVIDED TO TO PREVENT UNAUTHORIZED ENTRY. F. NO EQUIPMENT OR MATERIALS SHALL BE STORED OUTSIDE THE TEMPORARY FENCE FOR ANY AMOUNT OF TIME. 1. STRUCTURAL STEEL SHALL CONFORM TO THE FOLLOWING REQUIREMENTS, UNLESS NOTED OTHERWISE: WIDE FLANGE SHAPE: A992, 50KSI ANGLE AND CHANNEL SHAPE: ASTM A36, 36 KSI PLATE: ASTM A36, 36KSI PIPE: ASTM A53 GRADE B, 35 KSI HSS: ASTM A500 GRADE B, 46KSI 2. HIGH-STRENGTH BOLTS SHALL CONFORM TO ASTM A325: ONE HIGH-STRENGTH BOLT ASSEMBLY SHALL CONSIST OF A HEAVY HEX STRUCTURAL BOLT, A HEAVY NUT, A HARDENED WASHER CONFORMING TO ASTM F436. THE HARDENED WASHER SHALL BE INSTALLED AGAINST ELEMENT TURNED IN TIGHTENING. UNLESS NOTED OTHERWISE ON THE DRAWINGS, ALL CONNECTIONS SHALL BE BEARING TYPE CONNECTIONS. 3.WELDING ELECTRODES SHALL COMPLY WITH AWS D1.1 USING A5.1 OR A5.5 E70XX AND SHALL BE COMPATIBLE WITH THE WELDING PROCESS SELECTED. WELDERS SHALL BE QUALIFIED AS PRESCRIBED IN AWS D1.1. 4. UNLESS NOTED OTHERWISE ON THE DRAWING, ALL ANCHOR BOLTS SHALL CONFORM TO ASTM F1554 WITH HEAVY HEXAGONAL NUT. 5. FABRICATE ITEMS OF STRUCTURAL STEEL IN ACCORDANCE WITH AISC SPECIFICATION. 6. ALL EXPOSED STRUCTURAL STEEL AND BOLTS SHALL BE HOT DIP GALVANIZED PER ASTM A123. 7. SUBMIT FABRICATION AND ERECTION DRAWINGS SHOWING ALL DETAILS, CONNECTIONS, MATERIAL DESIGNATIONS, AND TOP STEEL ELEVATIONS FOR APPROVAL. THE SHOP DRAWINGS WILL BE REVIEWED FOR GENERAL CONFORMANCE TO THE CONTRACT DRAWINGS. SUCH APPROVAL SHALL NOT RELIEVE THE FABRICATOR/CONTRACTOR OF THE RESPONSIBILITY FOR EITHER THE ACCURACY OF THE DETAILED DIMENSIONS IN THE SHOP AND ERECTION DRAWINGS OR THE GENERAL FIT-UP OF PARTS THAT ARE TO BE ASSEMBLED IN THE FIELD. 8. PRIMER SHALL BE RED OXIDE-CHROMATE PRIME COMPLYING WITH STEEL STRUCTURES PAINTING COUNCIL (SSPC) PAINT SPECIFICATION NUMBER 11 1. DRILLING THROUGH EXISTING SLAB REBAR DURING POST-INSTALLED ANCHOR BOLTS INSTALLATION IS NOT PERMITTED. 2. POST-INSTALLED ANCHOR BOLT INSTALLATION SHALL BE PERFORMED BY PERSONNEL TRAINED TO INSTALL THE SYSTEM PER THE MANUFACTURER'S PRINTED INSTALLATION INSTRUCTIONS (MPII), AS INCLUDED IN THE ANCHOR PACKAGING. 3. EXPANSION AND ADHESIVE ANCHORS SHALL BE INSTALLED PER THE MANUFACTURER'S INSTRUCTIONS USING STANDARD EMBEDMENTS AND EDGE DISTANCES UNLESS NOTED OTHERWISE ON THE DRAWINGS. 1. COAT ALL SURFACES WITH AN ANTI-OXIDANT COMPOUND BEFORE MATING. 2. FOR GROUND BOND TO STEEL ONLY: INSERT A CADMIUM FLAT WASHER BETWEEN LUG AND STEEL, COAT ALL SURFACES WITH AN ANTI-OXIDANT COMPOUND BEFORE MATING. 3. ENSURE THE WIRE INSULATION TERMINATION IS WITHIN 1/8" OF THE BARREL (NO SHINERS). 4. ALL BELOW GRADE BONDS TO BE EXOTHERMIC WELDS OR IRREVERSIBLE COMPRESSION-TYPE CONNECTIONS LISTED FOR USE IN THE APPLICATION WHICH THEY ARE INSTALLED. 5. ALL HARDWARE SHALL BE STAINLESS STEEL 3/8" DIAMETER OR LARGER. ALL HARDWARE 18-8 STAINLESS STEEL INCLUDING LOCK WASHERS, COAT ALL SURFACES WITH AN ANTI-OXIDANT COMPOUND BEFORE MATING. USE CABLE WITH THE FOLLOWING MINIMUM PROPERTIES: 1. HIGH TENSILE STRENGTH >150 LB 2. TIGHT BUFFERED 3. INDOOR / OUTDOOR UV AND MOISTURE RESISTANT “RISER” CABLE 4. CONNECTOR TYPE: ST-ST 5. FIBER TYPE: MULTI-MODE 6-FIBER (3 PAIR) 62.5UM. 6 CONNECTORS ON BOTH ENDS. 6. JACKET: INDOOR/OUTDOOR RISER, BLACK 7. BREAKOUT: SIDE A: INNER END - 24 INCHES WITH 2MM FURCATION 7.A. SIDE B: OUTER END - 24 INCHES - 2MM FURCATION - STAGGERED EVERY 1" 8. WITH PULLING EYE ON SIDE B (OUTER END) AND SPOOL REEL DO NOT SCALE DRAWINGSCALL BEFORE YOU DIGCONTRACTOR NOTE FLOOD HAZARD AREA NOTE CODE REVIEW DRAWING INDEX DWG NO. DESCRIPTION CS-1 COVER SHEET GN-1 GENERAL NOTES GN-2 GENERAL NOTES A-0 COMMERCIAL SITE PLAN A-1 PROPOSED OVERALL LAYOUT PLAN A-2 EQUIPMENT LAYOUT D-1 CONSTRUCTION DETAIL D-2 CONSTRUCTION DETAIL E-1 ONE-LINE DIAGRAM E-1.1 BREAKER SETTINGS SITE INFORMATION VICINITY MAP PROJECT DESCRIPTIONAERIAL MAP COVER SHEET CS-1 SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY SHEET 1 OF 10 WALMART SUPERCENTER 2517 - SANTA ANA, CA ELECTRIC VEHICLE CHARGING STATIONS EA PROJECT #: 200056 3600 W. MCFADDEN AVENUE, SANTA ANA, CA 92704 THESE DRAWINGS ARE FORMATTED TO BE FULL SIZE AT 22"x34". CONTRACTOR SHALL VERIFY ALL PLANS & EXISTING DIMENSIONS & CONDITIONS ON THE JOB SITE & SHALL IMMEDIATELY NOTIFY THE ENGINEER IN WRITING OF ANY DISCREPANCIES BEFORE PROCEEDING WITH THE WORK OR BE RESPONSIBLE FOR SAME. Know what's below.Call before you dig. SITE NAME:WALMART SUPERCENTER 2517 - SANTA ANA, CA SITE ADDRESS:3600 W. MCFADDEN AVENUESANTA ANA, CA 92704 JURISDICTION:CITY OF SANTA ANA ZONING:SP2 (SPECIFIC PLAN - 2) PARCEL ID:144-561-01 SITE COORDINATES:N33° 44' 11.80" (N33.736656°) (NAD83) W117° 54' 59.2" (W117.916094°) (NAD83) GROUND ELEVATION:67.82'± (NAVD88) PROPERTY OWNER NAME:WALMART REAL ESTATE BUSINESS TRUST EQUIPMENT SUPPLIER:ELECTRIFY AMERICA1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 SITE SCALE: N.T.S.SCALE: N.T.S. NN 1.SUBJECT PROPERTY CLASSIFIED AS ZONE X, WHEN SCALED FROM FLOOD INSURANCE RATE MAP COMMCABINETY - MAP NUMBER 06059C0256J- DATED 12/3/2009 1.CONTRACTOR IS RESPONSIBLE FOR ANY NECESSARY REPAIRS OR REPLACEMENT DUE TO NEW CONSTRUCTION, OF EXISTING ELECTRICAL, PAVING, PVC CONDUITS, AND LIGHTS. ALL WORK AND MATERIALS SHALL BE PERFORMED AND INSTALLED IN ACCORDANCE WITH THE CURRENT EDITIONS OF THE FOLLOWING CODES AS ADOPTED BY THE LOCAL GOVERNING AUTHORITIES. NOTHING IN THESE PLANS IS TO BE CONSTRUED TO PERMIT WORK NOT CONFORMING TO THE LATEST EDITIONS OF THE FOLLOWING CODES: BUILDING CODE: ELECTRICAL CODE: FIRE SAFETY CODE: USE GROUP: CONSTRUCTION TYPE: 2022 CALIFORNIA BUILDING CODE (AMENDED 2021 IBC) 2022 CALIFORNIA ELECTRICAL CODE (AMENDED NFPA 70, 2020) 2022 CALIFORNIA FIRE CODE (AMENDED 2021 IFC) U (UTILITY) IIB ENGINEER CONTACT:TIMOTHY R. STORMONT, ARCHITECT CA LICENSE NO. C-15931(661) 619-0170 STORM-ARCH1@BAK.RR.COM SITE 1. REPLACE (3) SIGNET GEN III POWER CABINETS WITH (2) BTC GEN IV POWER CABINETS 2. REPLACE (3) SIGNET GEN III DISPENSERS (2 CCS AND 1 CHADEMO) WITH (3) BTC GEN IV DISPENSERS 4 Bldg #101122589 Elect #20185230 APPROVALS: PLNG C. Santana BLDG - CSG PUBLIC WORKS - Y. Soto ELECT - M. Smith PROPOSED OVERALL LAYOUT PLAN N A-11 A-1 22" x 34" SCALE: 1/4" = 1'-0" 11" x 17" SCALE: 1/8" = 1'-0" PROPOSED OVERALL LAYOUT PLAN SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY SHEET 5 OF10 NOTE: 1. CONTRACTOR TO FIELD-VERIFY EXISTING CONDUITS AT THE COMMENCEMENT OF CONSTRUCTION. CONTRACTOR TO REVIEW PROPOSED ROUTING (AS SHOWN IN PLANS) AND CONFIRM THE ACTUAL ROUTING (IF DIFFERENT FROM PLANS) WITH THE CONSTRUCTION MANAGER. PROPOSED BTC GEN IV DISPENSER STALL MODEL DISPENSER #kW CABLE TYPE EV 1 BTC GEN IV 1A 100 kW CCS EV 2 BTC GEN IV 1B 100 kW CCS EV 3 BTC GEN IV 2 100 kW CCS EXISTING XMFR EXISTING SWITCHGEAR 1 1A 1B 2 2 3 EV3 CCS EV2 CCS EV1 CCS PROPOSED BTC GEN IV CABINET ON PROPOSED PLINTH (TYP OF 2, SEE 1/D-1) EXISTING SIGNET GEN III CABINET TO BE REMOVED (TYP OF 3) 1 2 PROPOSED (2) 3" CONDUITS FROM BESS STUB-UP TO PROPOSED CABINET #2 PROPOSED BTC GEN IV DISPENSER (TYP OF 3, TO REPLACE EXISTING (3) SIGNET GEN III DISPENSERS: 2 CCS AND 1 CHADEMO) EQUIPMENT LAYOUT 1 A-2 22" x 34" SCALE: 1/2" = 1'-0" 11" x 17" SCALE: 1/4" = 1'-0" EXISTING EQUIPMENT LAYOUT 2 A-2 22" x 34" SCALE: 1/2" = 1'-0" 11" x 17" SCALE: 1/4" = 1'-0" PROPOSED EQUIPMENT LAYOUT SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY N SHEET 6 OF 10 NOTES: 1. CONTRACTOR TO PRESERVE EXISTING CONDUIT TO BE USED WITH NEW CABINETS. 2. CONTRACTOR TO VERIFY UNDERGROUND UTILITIES PRIOR TO CONSTRUCTION. 3. FACE OF DISPENSER TO FACE OF CURB (OR PARKING SURFACE) SHALL NOT EXCEED 10". 4. CONTRACTOR SHALL CLOSE/SEAL ALL GAPS AND OPENINGS IN PLINTHS AND PASS-THRU CONDUITS. 5. CONTRACTOR TO FIELD-VERIFY EXISTING CONDUITS AT THE COMMENCEMENT OF CONSTRUCTION. CONTRACTOR TO REVIEW PROPOSED ROUTING (AS SHOWN IN PLANS) AND CONFIRM THE ACTUAL ROUTING (IF DIFFERENT FROM PLANS) WITH THE CONSTRUCTION MANAGER. A-2 CONTRACTOR FIELD-CUT EXTENSION SIDES TO LENGTH (TYP) 3 A-2 22" x 34" SCALE: 1" = 1'-0" 11" x 17" SCALE: 1/2" = 1'-0" BTC GEN IV DISPENSER SLAB DETAIL N 3'-0" VERIFY IN FIELD 1'-312"5" 2' - 0 " 10 " 5' - 0 " VE R I F Y I N F I E L D 912" (MAX 10") FR O N T EXISTING CONDUIT WINDOW CONTRACTOR TO PROVIDE AND INSTALL (6) 5/8"Ø HILTI KWIK BOLT TZ2 SS 304/316 W/ 4-1/4" EMBEDMENT PROPOSED CONDUIT WINDOW EXISTING XMFR EXISTING XMFR EX I S T I N G SW I T C H G E A R EX I S T I N G SW I T C H G E A R SI G N E T G E N I I I PO W E R C A B I N E T 1 SI G N E T G E N I I I PO W E R C A B I N E T 2 SI G N E T G E N I I I PO W E R C A B I N E T 3 EXISTING SIGNET GEN III CABINET TO BE REMOVED (TYP OF 3) BT C G E N I V P O W E R CA B I N E T 1 BT C G E N I V P O W E R CA B I N E T 2 PROPOSED BTC GEN IV CABINET ON PROPOSED PLINTH (TYP OF 2, SEE 1/D-1; CONTRACTOR TO PROVIDE (6) 1/2" SS MACHINE BOLTS W/ WASHERS/NUTS FOR CABINET ANCHORAGE TO PLINTH) CONTRACTOR FIELD-CUT EXTENSION SIDES TO LENGTH (TYP) BTC GEN IV 12" AIR FLOW CLEARANCE EXISTING CONDUIT WINDOW PROPOSED CONDUIT WINDOW 4'-2" (4'-0" MIN) 412" 1'-012" 712" PROPOSED (2) 3" CONDUITS FROM BESS STUB-UP TO PROPOSED CABINET #2 ROUTE CONDUIT UNDERGROUND TO EAST SIDE OF FENCE AND THEN ABOVE GRADE AND INTO PLINTH EXISTING CONDUIT STUB-UP FOR BESS EXISTING CONDUIT STUB-UP FOR BESS 8" CONTRACTOR MAY NOTCH THE BOTTOM FLANGE OF THE PLINTH IN THE EVENT OF A CONDUIT STUB CONFLICT COMMERCIAL SITE PLAN A-0 SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY SHEET 4 OF 10 EXISTING XMFR N 1 A-0 22" x 34" SCALE: 1" = 10' 11" x 17" SCALE: 1" = 20' COMMERCIAL SITE PLAN 8'-0" WIDE FOR ACCESSIBLE SPACE & 5'-0" WIDE FOR OTHER DISABLED ACCESSIBLE SPACE PROPERTY LINE 283'-5" LANDSCAPE PLANTER LANDSCAPE PLANTER LANDSCAPE PLANTER LA N D S C A P E PL A N T E R LANDSCAPE PLANTER 9'-8"5'-0"9'-7"102'-1"6'-0"12'-0"9'-10" 2'-2" 7'-5" 1'-11" 34'-6" CO N C R E T E W A L K CONCRETE CURB CONCRETE CURB LANDSCAPE PLANTER 17 ' - 6 " 17 ' - 5 " 29 ' - 7 " 35'-5"108'-10"22'-1" 18 ' - 0 " 17 ' - 2 " EXISTING BUILDING LANDSCAPE PLANTER LANDSCAPE PLANTER LANDSCAPE PLANTER LANDSCAPE PLANTERLANDSCAPE PLANTERLANDSCAPE PLANTER LANDSCAPE PLANTER LANDSCAPE PLANTER LANDSCAPE PLANTER 34 ' - 8 " R7'-0" R1'-9" R1'-1" 26 ' - 6 " PROPOSED OVERALL LAYOUT PLAN N A-11 A-1 22" x 34" SCALE: 1/4" = 1'-0" 11" x 17" SCALE: 1/8" = 1'-0" PROPOSED OVERALL LAYOUT PLAN SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK REV DATE DESCRIPTION BY SHEET 4 OF 8 NOTE: 1. CONTRACTOR TO FIELD-VERIFY EXISTING CONDUITS AT THE COMMENCEMENT OF CONSTRUCTION. CONTRACTOR TO REVIEW PROPOSED ROUTING (AS SHOWN IN PLANS) AND CONFIRM THE ACTUAL ROUTING (IF DIFFERENT FROM PLANS) WITH THE CONSTRUCTION MANAGER. PROPOSED BTC GEN IV DISPENSER STALL MODEL DISPENSER #kW CABLE TYPE EV 1 BTC GEN IV 1A SHARED UP TO 360 kW CCS EV 2 BTC GEN IV 1B SHARED UP TO 360 kW CCS EV 3 BTC GEN IV 2 DEDICATED 360 KW CCS EXISTING XMFR EXISTING SWITCHGEAR 1 1A 1B 2 2 3 EV3 CCS EV2 CCS EV1 CCS PROPOSED BTC GEN IV CABINET ON PROPOSED PLINTH (TYP OF 2, SEE 1/D-1) EXISTING SIGNET GEN III CABINET TO BE REMOVED (TYP OF 3) 1 2 PROPOSED (2) 3" CONDUITS FROM BESS STUB-UP TO PROPOSED CABINET #2 PROPOSED BTC GEN IV DISPENSER (TYP OF 3, TO REPLACE EXISTING (3) SIGNET GEN III DISPENSERS: 2 CCS AND 1 CHADEMO) CORE PLINTH COVER CUT (AS NEEDED) FOR CONDUCTOR TO PASS-THRU MOUNTING BRACKET SIDE EXTENSION CORE PLINTH COVER END CAP END CAP SIDE EXTENSION MOUNTING BRACKET END CAP CORE PLINTH SIDE EXTENSION ORIFICE COVER MOUNTING PLATE (4) LAP PLATES PROVIDED W/ ASSEMBLY (CONTRACTOR TO PROVIDE, LOCATE, AND INSTALL WEDGE ANCHORS TOTAL 4, SEE NOTE 6) CUT-END OF SIDE EXTENSION TO ABUT CORE PLINTH (SEE NOTE 3) WEDGE ANCHORS (TYP 2 PER SIDE EXTENSION, SEE NOTE 4 & 6) NOTES: 1.POWER CABINETS SHALL BE ORIENTED PER A-2 LAYOUT. 2.CONTRACTOR TO PROVIDE AND INSTALL FASTENERS FOR POWER CABINETS. 3.THE CUT END OF SIDE EXTENSION SHALL ABUT THE PLINTH CORE. 4.THE LOWER FLANGE PILOT HOLES OF SIDE EXTENSION SHALL BE LOCATED AT END CAPS. 5.CONTRACTOR TO PROVIDE FIELD CUTS IN END CAPS FOR CONDUCTOR PASS THRU'S (WHEN NEEDED). 6.CONTRACTOR TO PROVIDE AND INSTALL 1/2"Ø WEDGE ANCHORS: 4 AT CORE, AND 2 FOR EACH SIDE EXTENSION. 7.CONTRACTOR SHALL ENSURE ALL OPENINGS ARE COVERED TO PREVENT ANIMAL/RODENT INGRESS. 8.CONTRACTOR TO SEAL ENTIRE BASE OF CORE PLINTH AND SIDE EXTENSIONS WITH WEATHERPROOF SEALANT. BOM PER PLINTH (PROVIDED BY FABRICATOR) PART QTY PART QTY CORE PLINTH 1 3/8"-16 X 1" STAINLESS STEEL SELF-TAPPING FLAT HEAD PHILLIPS SCREWS FOR CORE PLINTH COVER 4 CORE PLINTH COVER 1 3/8"-16 X 1" STAINLESS STEEL SELF-TAPPING PAN HEAD PHILLIPS SCREWS 48 SIDE EXTENSION 2 SPARE 3/8"-16 X 1" STAINLESS STEEL SELF-TAPPING FLAT HEAD PHILLIPS SCREWS 4 MOUNTING PLATE 4 SPARE 3/8" -16 X 1" STAINLESS STEEL SELF-TAPPING PAN HEAD PHILLIPS SCREWS 4 LAP PLATE 4 MOUNTING BRACKET 4 ORIFICE COVER 2 END CAP 3 FRONT FRONT FRONT FRONT CORE PLINTH SCALE: N.T.S. 1 D-1 UNIVERSAL PLINTH EXPLODED VIEW SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY CONSTRUCTION DETAIL SHEET 7 OF 10 D-1 DISPENSER ELEVATION DETAIL - BTC GEN IV 22" 98 . 2 4 " 16.8" LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW 36.63"30" 92 . 9 8 32.14" 30" 36 . 6 3 " POWER CABINET DETAIL CONSTRUCTION DETAIL NOT USED SCALE: N.T.S. 1 D-2 2 D-2 22" x 34" SCALE: 1/2" = 1'-0" 11" x 17" SCALE: 1/4" = 1'-0" 3 D-2 22" x 34" SCALE: 1/4" = 1'-0" 11" x 17" SCALE: 1/8" = 1'-0" SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY NOT USED SCALE: N.T.S. 4 D-2 6 D-2 SCALE: N.T.S. PLINTH ROUTING DIAGRAM SHEET 8 OF 10 D-2 NOT USED SCALE: N.T.S. 5 D-2 DISP. # PC # NEW DISP. # EV STALL EV1 2 EV3 1B PLINTH NEW PC # EV2 1A 21 21 3 21 3 CHAD. CHAD. SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY ONE-LINE DIAGRAM SHEET 9 OF 10 E-1 XMFR 30KVA 480 120/208V EXISTING GFCI RECEPTACLE IN WEATHERPROOF ENCLOSURE 30 A 1P S P A R E 30 A 1P S P A R E 30 A 1P S P A R E 50 A 3P40 0 A F 35 0 A T 3P 10 0 A 3P MA I N 30 A 1P EXISTING 300kVA TRANSFORMER 277/480V 3ɸ, 4W EXISTING GROUND (PER UTILITY SPEC) 1600AF 1000AT 3P W/ RELT GR N D NE U T M MAIN BREAKER SECTIONINCOMING SECTION 277/480V DISTRIBUTION SECTION 120/208V DISTRIBUTION SECTION EXISTING 1600A GE SWITCHBOARD 277/480V, 3ɸ, 4W 65KAIC WITH GROUND FAULT PROTECTION 1 GROUNDING ELECTRODE 5/8"x8'-0" COPPER CLAD GROUND ROD INSTALLATION PER NEC 250.52(A)(5), 250.53(A) AND 250.68 #3/0 AWG CU GROUNDING ELECTRODE CONDUCTOR PER NEC 250.66(A) MANUFACTURER PROVIDE MAIN BONDING JUMPER PER NEC 250.24(1)(4), 250.28(C), 250.8(A)(7) EXISTING CONCRETE ENCASED ELECTRODE PER NEC 250.52(A)(3)(1) OR (2) 6 1 E-1 SCALE: N.T.S. ONE-LINE DIAGRAM NOTES: 1. ALL ITEMS IN GRAY ARE PART OF AN EXISTING EVCS SYSTEM. ITEMS IN BLACK ARE PROPOSED. 2. CONTRACTOR TO DETERMINE BEST ROUTE FOR PLINTH AND CONNECTION TO EXISTING FOR THE PROPOSED CONDUCTOR ROUTING. 3. CONTRACTOR TO REMOVE (2) 300A BREAKERS AND REPLACE W/ (2) 600A BREAKERS PROVIDED BY CONSTRUCTION MANAGER. 4. PARALLEL CONDUCTOR LENGTHS SHALL BE EQUAL LENGTH FROM SWITCHGEAR TO GEN 4 POWER CABINETS. 5. ROUTE FROM SWITCHGEAR THROUGH EXISTING CONDUIT TO FORMER POWER CABINET LOCATION, CONTINUING VIA PLINTH TO PROPOSED POWER CABINET. 6. CONTRACTOR TO FIELD-VERIFY EXISTING CONDUIT SIZE AND QUANTITY AT THE COMMENCEMENT OF CONSTRUCTION. CONTRACTOR TO REVIEW AND COMPARE PROPOSED ROUTING (AS SHOWN IN PLANS) AND CONFIRM DISCREPANCIES AND ACTUAL ROUTING (IF DIFFERENT FROM PLANS) WITH THE CONSTRUCTION MANAGER. 7. CONTRACTOR TO RECONFIGURE 480V DISTRIBUTION SECTION TO ACCOMMODATE NEW 600A BREAKERS AS NEEDED. CONTRACTOR TO PROVIDE AND INSTALL FILLER PLATES, ETC. 8. BUTT SPLICING IS NOT PERMITTED, HOWEVER CONTRACTOR MAY RE-USE EXISTING CONDUCTORS IF SIZE AND MATERIAL MATCH THE WIRING SCHEDULE. 9. CONTRACTOR SHALL UN-TERMINATE AND REMOVE EXISTING CONDUCTORS. 10. THE FIXED IN PLACE EVSE HAS BEEN ADJUSTED TO 127 AMPS. PER NEC/CEC 625.42 THE EVSE ADJUSTED AMPERE SETTINGS SHALL BE PERMITTED TO BE THE AMPERE RATING OF THE EVSE. THE MEANS OF ADJUSTMENT SHALL HAVE RESTRICTED ACCESS THROUGH A PASSWORD ACCESSIBLE ONLY TO QUALIFIED PERSONNEL. 11. DUE TO THE SIZE OF THE TRANSFORMER, THE DISPENSERS ARE DE-RATED, WITH THE LOAD BEING 392A, WELL BELOW THE 1000A SETTING ON THE MAIN BREAKER. THE MAXIMUM SETTING AMPS PER POWER UNIT/CABINET IS 465 AMPS. THE 600A BREAKERS FEEDING THESE CABINETS SATISFY THE 125% BREAKER SETTING FOR THE FEEDER CIRCUITS PER NEC 70 TOTAL FLA LOAD SUMMARY CABINET FLA DISPENSER QUANTITY TOTAL LOAD DESCRIPTION BTC GEN IV CABINET 1 254A 2254 392A LIGHTS 1 A 1 1 L2 CHARGER 10A 1 10 20 A 1P 40 A 2P EXISTING L2 CHARGER 7 6 EXISTING SWITCHBOARD 120/208V SECTION EXISTING GFCI RECEPTACLE EXISTING (1) #12 AWG CU (THWN-2) (1) #12 AWG CU (THWN-2) NEUT (1) #12 AWG CU (THWN-2) EGC IN (1) EXISTING 3/4" CONDUIT 7 EXISTING L2 CHARGER EXISTING (2) #6 AWG CU (THWN-2) (1) #8 AWG CU (THWN-2) EGC IN (1) EXISTING 1" CONDUIT BTC GEN IV PC 2 SEE NOTE #9 60 0 A F 60 0 A T 3P 4 3 5 2A BTC GEN IV PC 1 BTC GEN IV DISPENSER 1A 60 0 A F 60 0 A T 3P 4 3 5 4 3 5 2 BTC GEN IV DISPENSER 1B EXISTING LIGHT 20 A 1P 8 2B 30 0 A F 30 0 A T 3P S P A R E SYSTEM ELECTRICAL CIRCUIT SCHEDULE 2 FROMNO TO CONFIGURATION 1 EXISTING UTILITY TRANSFORMER EXISTING SWITCHBOARD PROPOSED BTC GEN IV POWER CABINET #1 PROPOSED BTC GEN IV POWER CABINET #2 EXISTING (1) SPARE 3" CONDUIT (SEE NOTE #9) 3 4 5 PROPOSED BTC GEN IV POWER CABINET PROPOSED DISPENSER (DC POWER) PROPOSED (2) 350 MCM AL XHHW-2 1000V 90°C (1) #2 AWG CU GND THWN-2 600V 90°C IN EACH OF (2) EXISTING 2-1/2" CONDUITS PROPOSED BTC GEN IV POWER CABINET PROPOSED BTC GEN IV POWER CABINET PROPOSED DISPENSER (COMM) PROPOSED (1) FIBER OPTIC (MULTI-MODE 62.5/125 W/ ST CONNECTORS) (1) 2-CONDUCTOR #16 AWG TSP (1) CAT-6 IN (1) EXISTING 1-1/2" CONDUIT PROPOSED DISPENSER (AUX POWER) PROPOSED (2) #10 AWG CU (1) #10 AWG CU GND IN (1) EXISTING 3/4" CONDUIT EXISTING (6) 4" CONDUITS (PER UTILITY DESIGN) EXISTING SERVICE EQUIPMENT PROPOSED (3) 500 MCM AL THWN-2 600V 90°C (1) #1 AWG CU GND THWN-2 600V 90°C IN EACH OF (2) EXISTING 3" CONDUITS EXISTING SERVICE EQUIPMENT: CIRCUIT 1 (600A) SEE NOTE #3 2A 8 EXISTING LIGHTS EXISTING (1) #12 AWG CU (THWN-2) (1) #12 AWG CU (THWN-2) NEUT (1) #12 AWG CU (THWN-2) EGC IN (1) EXISTING 1-1/4" CONDUIT EXISTING BESS STUBS 2B 2B EXISTING SERVICE EQUIPMENT: CIRCUIT 2 (300A) SPARE PROPOSED BTC GEN IV POWER CABINET #22B PROPOSED (3) 500 MCM AL THWN-2 600V 90°C (1) #1 AWG CU GND THWN-2 600V 90°C IN EACH OF (2) EXISTING 3" CONDUITS & EACH OF (2) 3" CONDUIT EXTENSIONS 9 10 NOT USED EXISTING SWITCHBOARD 120/208V SECTION EXISTING SWITCHBOARD 120/208V SECTION 2B EXISTING SERVICE EQUIPMENT2C 2C EXISTING BESS STUB-UP EXISTING (1) SPARE 3" CONDUIT (4) SPARE 1-1/4" CONDUITS BTC GEN IV DISPENSER 2 NOT USED EXISTING SERVICE EQUIPMENT: CIRCUIT 3 (600A) SEE NOTE #3 127A 1127BTC GEN IV CABINET 2 DISPENSER (kW) 100kW, 100kW 100kW SEE NOTE 10 SEE NOTE 10 SEE NOTE 10 *SEE NOTE 10 *SEE NOTE 10 QTY 1 1 4 EXISTING BREAKER IS RATED AT 1000A PROPOSED LOAD IS BELOW 1000A SHEET TITLE JOB NAME 200056 -LEGACY SWAP WALMART SUPERCENTER 2517 3600 W. MCFADDEN AVENUE SANTA ANA, CA 92704 ELECTRIFY AMERICA, LLC 1950 OPPORTUNITY WAY, SUITE 1500 RESTON, VA 20190 CHECKED BY: RBH 1 9-30-24 CD100 S&S AAL 2 10-16-24 CD100 S&S YK 3 2-17-25 CD100 S&S GA 4 4-7-25 S&S GA REV DATE DESCRIPTION BY BREAKER SETTINGS SHEET 10 OF 10 E-1.1 1 E-1.1 SCALE: N.T.S. BREAKER SETTINGS NOTE: EXISTING CONFIGURATION MATCHES THE ONE-LINE DIAGRAM ON SHEET E-1. BREAKER IS RATED AT 1000A. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL BTCPOWER, INC. 1719 S. GRAND AVE. SANTA ANA, CA 92705 WWW.BTCPOWER.COM 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 2 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D PLEASE NOTE This document contains useful general information about the product and its installation. BTCPower, Inc. reserves the right to make changes to this product without further notice. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without written permission of BTCPower, Inc. Changes or modifications to this product by other than an authorized service facility could void the product warranty. If you have questions about the use of this product, contact your customer service representative. This product should be operated by trained personnel only. MANUFACTURER: www.btcpower.com OFFICE ADDRESS: 1719 S. Grand Ave., Santa Ana, CA 92705 CONTACT INFORMATION: Phone: 1-714-259-4888 Fax: 1-714-259-0840 Email: sales@btcpower.com This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 3 of 89 TABLE OF CONTENTS Table of Contents 1. Safety Guidelines ................................................................................................................... 5 1.1. Important Safety Instructions ................................................................................................. 5 1.2. Symbols and Definitions ......................................................................................................... 6 2. System Overview ................................................................................................................... 7 3. Equipment Description .......................................................................................................... 8 3.1. System Components ............................................................................................................ 10 3.2. Labels and Markings ............................................................................................................ 11 4. System Specification ........................................................................................................... 13 4.1. DCFC Power Unit .................................................................................................................. 13 4.2. DCFC Dispenser ................................................................................................................... 14 5. Pre-Installation ...................................................................................................................... 15 5.1. Location Selection ............................................................................................................... 15 5.2. Cable Reach ........................................................................................................................ 16 5.3. ADA Consideration .............................................................................................................. 17 5.4. List of Parts, Materials, and Tools Needed for Installation ................................................. 19 6. Transportation and Handling ............................................................................................... 20 6.1. Packaging ............................................................................................................................ 20 6.2. Transport, Handling, and Storage ....................................................................................... 20 6.3. Receiving and Unpacking .................................................................................................. 21 7. Installation ............................................................................................................................ 22 7.1. Moving and Hoisting Instructions ........................................................................................ 23 7.2. Mounting Procedures .......................................................................................................... 26 7.2.1. Clearance Around the Unit ................................................................................................. 26 7.2.2. Tower and Dispenser Mounting .......................................................................................... 28 7.3. Electrical and Communication Service Connection ........................................................ 31 7.4. Dispenser MCU Dipswitch Settings ...................................................................................... 43 8. Verification and Inspection ................................................................................................. 44 9. Operation ............................................................................................................................. 45 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 4 of 89 TABLE OF CONTENTS 9.1. System Power Up .................................................................................................................. 45 9.1.1. Reset Breaker/GFCI .............................................................................................................. 47 9.2. Output Connectors .............................................................................................................. 48 9.2.1. CCS1 Connector (500 A) ..................................................................................................... 48 9.3. Simultaneous Charging Method ......................................................................................... 49 9.4. Troubleshooting .................................................................................................................... 50 10. Maintenance ........................................................................................................................ 69 11. Product Disposal .................................................................................................................. 76 12. Appendix .............................................................................................................................. 77 12.1. Component Information ..................................................................................................... 77 a) CCS1 High-Power Liquid Cooled Coupler (500A Rated) .................................................. 77 b) Cooling Unit System ............................................................................................................. 78 c) Cool Cable Coolant ............................................................................................................ 78 12.2. Cooling Unit System Overview ............................................................................................ 87 a) Main Parts ............................................................................................................................. 87 b) Fill Level of Cooling Unit ....................................................................................................... 87 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 5 of 89 SAFETY GUIDELINES 1. Safety Guidelines SAVE THESE INSTRUCTIONS This document contains important instructions for the installation, operation, and maintenance of 360kW High Power DC Charger. These instructions should be retained for future reference. 1.1. Important Safety Instructions DANGER READ THIS MANUAL BEFORE YOU BEGIN This 360kW High Power DC Charger manages electricity and may be hazardous. The equipment should be installed, adjusted, and serviced only by qualified electrical personnel familiar with the construction and operation of this type of equipment and the hazards involved, and in full compliance with all local and national codes and standards. Failure to observe this precaution could result in severe injury or death. Read this manual completely and become familiar with the equipment prior to performing any procedures specified in the manual and energizing the equipment. Inspection and maintenance of this equipment should be performed in accordance with the procedures detailed in this manual. In situations where it is not possible to perform an installation following the procedures stated in this document, contact BTCPower, Inc. BTCPower, Inc. will not be responsible for any damages that may occur resulting from custom installations that are not stated in this document. There are no user serviceable parts inside. For service, please contact customer service or your local distributor. DO NOT ATTEMPT TO REPAIR THE CHARGE STATION YOURSELF. SERVICE TO THE UNIT SHALL ONLY BE PERFORMED BY A QUALIFIED PERSONNEL. If the charging cable is somehow damaged, do not operate the charge station. Contact your service representative for service immediately. Shut down the power to the tower by switching the breaker on the supply panel to the off position. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 6 of 89 SAFETY GUIDELINES 1.2. Symbols and Definitions Please take special attention to all information marked with the following symbols. These symbols may be found throughout the manual and on labels affixed to the equipment unit. DANGER Indicates High Voltage. It calls attention to items or operations that could be dangerous to person/s operating this equipment. Read and follow the instructions carefully. Failure to do so will result in severe injury or possibly death. WARNING Indicates a hazard or unsafe practice which, if not avoided, may result in severe injury or possibly death. CAUTION Indicates a hazard or unsafe practice which, if not avoided, may result in minor to moderate injury. NOTE Indicates important information to consider, otherwise, improper installation and/or damage to components may occur. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 7 of 89 SYSTEM OVERVIEW 2. System Overview The 360kW High Power DC Charger converts a 480VAC 3-phase voltage into DC voltage to directly charge an electric vehicle’s lithium-ion battery. It is capable of charging all electric vehicles compliant with Combined Charging System (CCS) standards. The charger is composed of one (1) 360kW Power Unit (with 4 individually controlled 90kW Groups on it) and one or two dispenser/s depending on the configuration. The dispenser has a default CCS configuration and is 500A-rated. ➢ SIMPLIFIED BLOCK DIAGRAM (1-DISPENSER SYSTEM): ➢ SIMPLIFIED BLOCK DIAGRAM (2-DISPENSER SYSTEM): This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 8 of 89 EQUIPMENT DESCRIPTION 3. Equipment Description 360 kW POWER UNIT / TOWER COMPONENT DESCRIPTION 1. Fans 2. Fiber-Optic Transceiver 3. Interlock 4. Power Supplies 5. Input Terminal Lugs 6. Ground Lugs 7. Control Box 8. DC Contactor Matrix 9. 30kW Power Modules (up to 12 total) 10. AC Contactors 11. Circuit Breakers 12. Output Terminal Lugs This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 9 of 89 EQUIPMENT DESCRIPTION 500A CHARGE DISPENSER COMPONENT DESCRIPTION 1. 15-inch Outdoor-Rated Display and Touch Screen 2. HMI Navigation Buttons 3. NAYAX VPOS Encrypted Insert Card Reader 4. High Security Lock #1 5. High Security Lock #2 6. RFID Card Reader 7. Charging Connector 8. Power Supply 9. Fiber-Optic Transceiver 10. Circuit Breaker 11. DC Input 12. MCU Board 13. Cooling Unit - Heat Exchanger 14. AC Input 15. Interlock 16. Fiber-Optic Connections 17. Ground Connections 18. Cooling Unit - Pump/Tank This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 10 of 89 EQUIPMENT DESCRIPTION 3.1. System Components Power Unit / Tower ITEM DESCRIPTION SKU 1 Gen 4 HPC 480VAC Tower/Power Cabinet 360kW Dual Output HPCT2-360-480-2 Dispenser ITEM DESCRIPTION SKU 1 Electrify America Cycle 3 500A Level 4 Dispenser CCS1 only HPCD6-500-05-005 2 Electrify Canada Cycle 3 500A Level 4 Dispenser CCS1 only HPCD6C-500-05-005 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 11 of 89 EQUIPMENT DESCRIPTION 3.2. Labels and Markings DATE OF MANUFACTURE The tower and dispenser units come with an identifier label attached to identify the date of manufacturing. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 12 of 89 EQUIPMENT DESCRIPTION LOCATION OF LABELS Tower Dispenser This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 13 of 89 SYSTEM SPECIFICATION 4. System Specification 4.1. DCFC Power Unit AC to DC Power Converter Specification SKU: HPCT2-360-480-2 PARAMETER HPCT2-360-480-2 AC Input Input Voltage Range 480 VAC, 3 Phase, +10% / -15% Input Frequency Range 47 – 63 Hz Input Current @ 480 VAC 465 A Panel Breaker 600A Power Factor > 0.99 full load Total Harmonic Distortion < 5% Efficiency at Full Load > 94% SCCR 65kA AC Output Number of Outputs 2 Voltage 480VAC, Split Phase Current 6A DC Output Output Voltage Range 200 – 950 VDC Number Of Outputs 2 Max Output Current (per output) 500A Maximum Output Power 360 kW Minimum Output Current 5A Output Ripple Current < 15 Ap–p (Bandwidth 1 kHz) Protection Over Temperature Self–protected and latched Output Over Voltage Output Shutdown and Latched Output Overload Output Shutdown and Latched CAN Communication Loss 1 sec Shutdown Upon Loss of Connection Reverse Feed Back Feed Protection Safety Standards Isolation UL 2202 EMC Standards Harmonics IEC 61000-3-12 Emissions FCC and IEC 61851-21-2 Immunity UL 2231-2 Environment Conditions Operating Temperature Range -30°C to +50°C Operating Altitude 2,000 meters Humidity 95% Non-Condensing Mechanical Characteristics Dimensions 30” W x 34.5” D x 93” H Weight 1655 lbs Enclosure IK Rating IK 10 Enclosure IP Rating IP 54 (NEMA 3R) *Specifications are subject to change, without prior notice. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 14 of 89 SYSTEM SPECIFICATION 4.2. DCFC Dispenser High Power Dispenser Specification SKU: HPCD6-500-05-005 PARAMETER DISPENSER 500A Rated AC Input Auxiliary Input Voltage 480 VAC, Split Phase, +/-10% (L1, L2, Ground) Auxiliary Input Current 6A @ 480 VAC Input Frequency Range 60 Hz ± 10 % DC Input Input Voltage Range 200 - 950 V Input Current Range 5 – 500 A DC Output CCS Configuration Maximum DC Output Current CCS, continuous 500 A Environment Conditions Operating Temperature Range -30°C to +50°C Operating Altitude 2,000 m Humidity 5-95% non-condensing Mechanical Characteristics Enclosure IK Rating IK 10 Enclosure IP Rating IP 54 (NEMA 3R) Dimensions Footer: 22” (W) x 16.8” (D) x 96.8” (H) Overall: 31.5” (W) x 18.7” (D) x 96.8” (H) Weight 551 lbs *Specifications are subject to change, without prior notice. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 15 of 89 PRE-INSTALLATION 5. Pre-Installation Prior performing any installation activities, it is important to go through each of the items outlined in this section which are essential for the installation process. 5.1. Location Selection Thing to consider when choosing a location to install the unit: • Standards for Accessible Design (refer to section 5.3) • Conformance to all governing standards for location and placement of the charger • Communications Connectivity o Refer to BTCPower guidelines in “Determining Suitability of Site for Cellular Connectivity” o Ensure that installation location meets the Cellular Signal Strength Criteria below Parameter Min Value Device Notes RSSI -69 dBm SureCall If RSSI < - 69dBm, measure RSRP, RSRQ, and SNIR RSRP -100 dBm Squid or BTC-Cellular Meter Please consult BTCPower Application Engineering RSRQ -11 dBm Squid or BTC-Cellular Meter Please consult BTCPower Application Engineering SNIR > 6 dB Squid or BTC-Cellular Meter For Reference • Local Conditions o This unit is not intended to be used in a commercial garage (Repair Facility) or closer than 20 feet (508 mm) of an outdoor fuel dispenser device. If installation in either of these conditions requires, then mounting method to ensure no arching components are located below 18 inches from the driving surface required. o Area is not exposed to temperatures in excess of 50°C, corrosive fumes, combustible materials, or explosive gases o Clearances at both sides for proper ventilation o Clearance at front and sides for accessibility during service (refer to Section 7.2.1) o Wiring and conduit needed to connect the charger to the circuit panel o Location of vehicle’s charging inlets while parked o Use of protective bollards and wheel stops to protect the charger This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 16 of 89 PRE-INSTALLATION 5.2. Cable Reach In its default configuration, the dispenser comes with a CCS1 cable (length of 17.7 feet with cable retraction operating). The figure shows the radius in which the connector can be used. 17.7 feet This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 17 of 89 PRE-INSTALLATION 5.3. ADA Consideration STANDARDS FOR ACCESSIBLE DESIGN for Americans with Disabilities is applicable when choosing the location and placement of all Electric Vehicle Supply Equipment. The following is a direct excerpt from the 2010 ADA Standards for Accessible Design: http://www.ada.gov/2010ADAstandards_index.htm “The Department of Justice published revised regulations for Titles II and III of the Americans with Disabilities Act of 1990 “ADA” in the Federal Register on September 15, 2010. These regulations adopted revised, enforceable accessibility standards called the 2010 ADA Standards for Accessible Design “2010 Standards” or “Standards”. The 2010 Standards set minimum requirements – both scoping and technical – for newly designed and constructed or altered State and local government facilities, public accommodations, and commercial facilities to be readily accessible to and usable by individuals with disabilities. Adoption of the 2010 Standards also establishes a revised reference point for Title II entities that choose to make structural changes to existing facilities to meet their program accessibility requirements; and it establishes a similar reference for Title III entities undertaking readily achievable barrier removal. The Department has assembled this online version of the official 2010 Standards to increase its ease of use. This version includes: • 2010 Standards for State and Local Government Facilities Title II • 2010 Standards for Public Accommodations and Commercial Facilities Title III The Department has assembled into a separate publication the revised regulation guidance that applies to the Standards. The Department included guidance in its revised ADA regulations published on September 15, 2010. This guidance provides detailed information about the Department’s adoption of the 2010 Standards including changes to the Standards, the reasoning behind those changes, and responses to public comments received on these topics. The document, Guidance on the 2010 ADA Standards for Accessible Design, can be downloaded from: http://www.ada.gov This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 18 of 89 PRE-INSTALLATION For information about the ADA, including the revised 2010 ADA regulations, please visit the Department’s website www.ADA.gov; or, for answers to specific questions, call the toll-free ADA Information Line at 800- 514-0301 (Voice) or 800-514-0383 (TTY).” Compliance to ADA Standards Access to all the controls and commands including the buttons and the card reader, must comply with local codes and ADA requirements. That includes being under 48” of distance to the ground. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 19 of 89 PRE-INSTALLATION 5.4. List of Parts, Materials, and Tools Needed for Installation Parts & Materials Needed to Purchase Item Part Description Quantity Remarks 1 OM3, multimode, 50/125µm, ST connectors on both ends 1 pair per dispenser Recommended suppliers: https://fibercablesdirect.com/ 2 18AWG Twisted Pair, Shielded, Interlock Cable 1 pair per dispenser 3 DC Wire 1-2 Pair per dispenser (Parallel option recommended) 4 480VAC Single Phase Wire 1 pair per dispenser (L1, L2, Ground) *Note: Extra sets of Fiber Optic Connectors are needed as back-up since these are brittle. Tools/Materials Needed during Installation Item Part Description Quantity 1 Philips Head Screwdriver 1 2 ½” x 4” Concrete Expansion Bolt 10 or 16 (Depending on # of Dispensers being installed) 3 ½” Torque Wrench 1 4 Allen Wrench Set 1 5 Keys (shipped with the unit) 1 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 20 of 89 TRANSPORTATION AND HANDLING 6. Transportation and Handling 6.1. Packaging The tower and dispenser are packaged, shipped, and delivered in wood crates. Below are the details of its packaging and dimensions for both tower and dispenser. Item Width (in) Depth (in) Height (in) Weight (lb) Power Unit / Tower 39 47.3 99.2 1655 lbs Dispenser 37.7 29.5 102” 551 lbs 6.2. Transport, Handling, and Storage Transport The tower and dispenser must be transported upright or in vertical position. Liquid may leak or other materials may get damaged if tilted or transported on its side. Moving and Hoisting Forklift or pallet truck can be used in moving or transporting the tower and dispenser. In addition to this, the tower and dispenser can be moved or lifted using the lifting eye bolts. Refer to section 7.1 for more details. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 21 of 89 TRANSPORTATION AND HANDLING Storage The tower and dispenser must be stored in its original wood packaging in a dry environment from -30°C to +50°C. 6.3. Receiving and Unpacking Receiving Instructions Once shipment is received, please follow these receiving instructions. It is the responsibility of the receiver to perform visual inspection on the shipment and immediately notify BTCPower Project Manager for any damage. • Unload and carefully inspect the crate or packaging for any damage caused by mechanical impacts or any incidents during its transportation. • Inspect the Tip N Tell tilt indicator attached on the crate. Tip N Tell tilt indicator provides information of the shipment conditions during transit. Blue beads in arrow indicates crate has been on its side or tipped over in transit. • Note on the delivery receipt any visible damage to the crate/packaging or shipment has been tipped based on the Tip N Tell tilt indicator. Provide information of the damage as detailed as possible. • For any issues or questions regarding the shipment, please call BTCPower Shipment In-charge at (714) 706 – 4970. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 22 of 89 INSTALLATION 7. Installation SAFETY INSTRUCTIONS The 360kW High Power DC Charger should be installed in accordance with local codes and all applicable ordinances including the Canadian Electric Code, Part I. Read all installations instructions carefully prior to performing the installation. DANGER – HIGH VOLTAGE The equipment utilizes high voltages, only qualified electrical personnel familiar with the operation and construction should install, adjust, modify, and service this equipment. Failure to observe this precaution could result to severe injury or death. WARNING • The equipment may be installed outdoors but only use under environment conditions as stated in this document. • Do not perform any live wire operations. • Do not touch the inside of the equipment while it is running. • Disconnecting means must be adjacent to or within sight of equipment. • This equipment includes capacitive components such as electrolytic capacitors. Some parts may remain charged inside of the unit even after the input power is disconnected. • This 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. • Personal Protective Equipment (PPE) should be always used when working with the equipment. • Equipment should not be opened and serviced in rain or snow conditions. CAUTION During installation of the unit, ensure that the charge station’s supply cable is in such a way that it will not be tripped over, stepped on, pulled on, or somehow subjected to damage or stress. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 23 of 89 INSTALLATION 7.1. Moving and Hoisting Instructions CAUTION Improper handling may result to severe injury and/or damage to the unit due to dropping or falling. Make sure to follow specified procedures for hoisting operations. Take necessary measures to prevent falling when moving or hoisting the unit. Using Forklift or Pallet Jack • Care should always be taken when lifting the charger using a forklift or pallet jack. • Forks should be extended completely under the unit to avoid accidents. Using Lifting Eye Bolts The Power Unit / Tower comes with four (4) M12 Lifting Eye Bolts positioned at each corner of the unit enclosure’s top surface. The Working Load Limit (WLL), commonly referred as Lifting Capacity, of the M12 Lifting Eye Bolt is 0.34t or equivalent to 680 lbs. Eye bolt capacity reduces as the horizontal angle decreases. Use eye bolts at a vertical angle of no more than 15°. Eye bolt strength at 15° angle drops down to 80% of vertical lifting capacity. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 24 of 89 INSTALLATION BTCPower’s recommendation in reference to the M12 lifting eye bolt specification and the charger’s maximum weight, is to use all four (4) eye bolts and keep the vertical angle between 0° to 15° when lifting. • Calculation o Total Lifting Capacity (4 eye bolts) = 4 x 680 lbs = 2,720 lbs o Estimated Tower Weight = 1655 lbs o Estimated Dispenser Weight = 551 lbs o Total Lifting Capacity at 15° (20% reduction) = 80% x 2,720 lbs = 2,176 lbs This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 25 of 89 INSTALLATION NOTE After the Power Unit / Tower is fixed on its location, the lifting eye bolts must be removed, and end sealing protections must be inserted into the holes. POWER UNIT / TOWER DISPENSER This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 26 of 89 INSTALLATION 7.2. Mounting Procedures 7.2.1. Clearance Around the Unit Clearance surrounding the unit must be considered for proper ventilation and service accessibility. Refer to the installation drawings as illustrated below. Power Unit / Tower Installation Drawing This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 27 of 89 INSTALLATION This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 28 of 89 INSTALLATION Dispenser Installation Drawing 7.2.2. Tower and Dispenser Mounting Both the Tower and Dispenser must be fixed on a concrete pad. The Tower requires four (4) ½" x 4" (P/N RHPA-3830) concrete expansion bolts, and the Dispenser requires six (6) ½" x 4" (P/N RHPA- 3830) concrete expansion bolts or as determined appropriate by the structural engineer in- charge. Make sure to check local codes for compliance. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 29 of 89 INSTALLATION Power Unit / Tower Footer Drawing The illustration below shows the drilling layout for the Power Unit / Tower. Four (4) points are needed to fix the unit on the concrete pad. The front mounting holes MUST be used, but for the rear, either set of the back mounting holes may be used. The conduit entry to the unit is also shown. Base foundation template for alignment and hole location is available in .step or .dxf files upon request. NOTE The bottom of the tower needs to be sealed to the ground. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 30 of 89 INSTALLATION Dispenser Footer Drawing The illustration below shows the drilling layout for the Dispenser. Six (6) points are needed to fix the unit on the concrete pad. The conduit entry to the unit is also shown. Base foundation template for alignment and hole location is available in .step or .dxf files upon request. NOTE The bottom of the dispenser needs to be sealed to the ground. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 31 of 89 INSTALLATION 7.3. Electrical and Communication Service Connection 1-Dispenser Configuration System 2-Dispenser Configuration System *Coordination of conductor sizes with overcurrent protection shall be in accordance with the Canadian Electrical Code, Part I. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 32 of 89 INSTALLATION Power Unit / Tower Requirements • AC Input: 480 VAC, 3-Phase, 465 Amps FLA (Full Load Amps) • DC Output (to Dispenser): 950 V ➢ Dispenser 1: Use this channel for Single Dispenser or 1st Dispenser ➢ Dispenser 2: Use this channel for the 2nd dispenser • Communication conduit between the tower and the dispenser ➢ FOC (Fiber Optic Connection): o OM3, multimode, 50/125µm, ST connectors on both ends o 2 pairs of Fiber Optic Cables (1 pair as spare since these are brittle) ➢ Interlock Connection: o 18 AWG twisted pair, shielded interlock cable Dispenser Requirements • AC Input: 480 VAC, Split Phase, 6 Amps FLA (Full Load Amps) ➢ 3 conductors (L1, L2, G) 16-6AWG, 600V Rated, (1-slot at TB1 is spare) • DC Input (from Tower): 950 V • Communication conduit between the tower and the dispenser ➢ Fiber Optic Connection from tower (2 pairs per dispenser with 1 as spare) ➢ Interlock Connection from tower (1 pair per dispenser) • MUST have a common direct ground with the Tower Grounding Instructions DANGER – HIGH VOLTAGE Improper connection of the equipment-grounding conductor may result in a risk of electric shock. Check with a qualified electrical personnel or service person if you are in doubt as to whether the unit is properly grounded. The 360kW High Power DC Charger must be connected to a grounded, metal, permanent wiring system, or an equipment-grounding conductor is to be run with the circuit conductors and connected to the equipment grounding terminal. Connections to the charger shall comply with all applicable electrical codes and ordinances. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 33 of 89 INSTALLATION TOWER AC Input – Input Terminal Lug and Ground Lug Terminal Lug P/N Opening per Pole Wire Range Torque Requirement 2-600L2 2 600kcmil – 2AWG (copper or aluminum) 46 lb-ft Ground Lug P/N Opening per Pole Wire Range Torque Requirement 600TP 6 600kcmil – 2AWG (copper or aluminum) 46 lb-ft • Use 90°C Wire. • Copper: 2 wires of 350 kcmil - 600 kcmil per Input Phase • Aluminum: 2 wires of 500 kcmil - 600 kcmil per Input Phase • Termination Lugs are rated to +90°C DANGER – HIGH VOLTAGE Installer shall put “DANGER – HIGH VOLTAGE” label in clearly visible area near the grid wiring. NOTE The system is not phase rotation sensitive, thus there is no concern over the phasing of the termination of the AC Lines. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 34 of 89 INSTALLATION TOWER DC Output Terminal Lug • Single or Dual High Output Configuration Terminal Lug P/N Opening per Pole Lug Wire Range Torque Requirement 2-600L2 2 600kcmil – 2AWG (copper or aluminum) 46 ft-lb NOTE Wire should be 1,000V rated (minimum) and suitable for 500A. NOTE • Dispenser 1: Use this channel for Single Dispenser or 1st Dispenser • Dispenser 2: Use this channel for the 2nd Dispenser This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 35 of 89 INSTALLATION 500A Dispenser DC Input Terminal Lug Terminal Lug P/N Opening per Pole Wire Range Torque Requirement 2-600L2 2 600 kcmil - 2 AWG 46 lb-ft • Use 90°C Wire. o Copper: 2 wires of 250 kcmil - 600 kcmil per Input Phase o Aluminum: 2 wires of 350 kcmil - 600 kcmil per Input Phase • Termination Lugs are rated to +90°C NOTE Wire should be 1,000V rated (minimum) and suitable for 500A. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 36 of 89 INSTALLATION Tower DC Output to Dispenser DC Input Torque Requirement: 46 ft-lb This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 37 of 89 INSTALLATION Dispenser DC Grounding The dispenser must have a common direct ground with the Power Unit / Tower. Torque Requirement: Copper Ground Lugs: 16 lb-ft This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 38 of 89 INSTALLATION Tower to Dispenser AC Auxiliary Grounding This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 39 of 89 INSTALLATION Tower to Dispenser 480VAC Split-Phase Auxiliary Circuit Torque Requirement: 14 in-lb This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 40 of 89 INSTALLATION Fiber-Optic and Interlock Routing Information The Fiber-Optic and Interlock Cables must be routed through the panduit. This is to prevent damage to the cable from the front door and cable management. Remove this panduit cover and route the interlock and fiber-optic cables through the panduit This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 41 of 89 INSTALLATION Tower to Dispenser Interlock Connection Torque Requirement: 5 in-lb This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 42 of 89 INSTALLATION Tower to Dispenser Fiber Optic Cable Connection Dispenser 1 Dispenser 2 FO2 FO1 The Fiber-Optic landings have a “TX” (transmit) and an “RX” (receive) port. When connecting the fiber optic lines, ensure the “TX” port from one end connects to the “RX” port on the other end, and vice versa. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 43 of 89 INSTALLATION 7.4. Dispenser MCU Dipswitch Settings All dispensers come in a default setting (Dispenser 1). In case two (2) dispensers are installed, the 2nd dispenser needs to be configured as Dispenser 2. The MCU is accessible upon opening the dispenser as shown below. NOTE: Only configure the dipswitch indicated below. Dipswitch Settings This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 44 of 89 VERIFICATION AND INSPECTION 8. Verification and Inspection Commissioning Prior and during system start-up, perform verification and inspection on both tower and dispenser/s using the 360kW HPDC Charger Commissioning Checklist which was provided together with this manual. All instructions listed in the commissioning checklist are considered mandatory and must be carried out by the contractor in-charge of the commissioning. Required information and actual measured data shall be filled-in as well. For any issues, concerns, or questions during commissioning, please email to dispatch@btcpower.com or call 1-855-901-1558. After successful commissioning, email the completed commissioning checklist to dispatch@btcpower.com. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 45 of 89 OPERATION 9. Operation 9.1. System Power Up DANGER The charger must NOT be started or put into use without having been commissioned by a fully trained and authorized personnel. Dispenser • SWITCH ON the circuit breaker and GFCI inside the Dispenser as shown below. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 46 of 89 OPERATION Tower • SWITCH ON the auxiliary breaker inside the Tower as shown below. • SWITCH ON the circuit breakers inside the Tower as shown below. (Proceed to section 9.1.1 on resetting the breaker/GFCI if tripped.) • Then, SWITCH ON the Main Panel Breaker. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 47 of 89 OPERATION 9.1.1. Reset Breaker/GFCI 1. If tripped, “Reset” button is up and the switch is in the middle position. 2. To reset, press the reset button and set the switch to “off” position. 3. Then turn “ON” circuit breaker This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 48 of 89 OPERATION 9.2. Output Connectors DANGER – HIGH VOLTAGE Danger of death, serious personal injury, and burns. Improper handling of the charging cable can cause electric shock and short circuits. 9.2.1. CCS1 Connector (500 A) • Cable Length: 17.7 feet • Connector Weight: 1.98 lbs. • Outer Cable Weight (including coolant): 11.57 lbs This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 49 of 89 OPERATION 9.3. Simultaneous Charging Method Single Output First In, First Out: Immediate Charge Payment Available/Required *500A Max is possible from Tower but depends on dispenser **Some vehicles do not allow feature 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 50 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION 9.4. Troubleshooting Error Codes ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS SECC_OFFLINE Dispenser 1 High SECC board is not communicating with charger. No communication with SECC for > 30 sec - Contact BTC power for assistance - Attempt to connect via ethernet - Reflash SECC board(s) if possible - If SECC reflash does not correct issue, reboot MCU - Technician may be dispatched if issue cannot be solved remotely - Visually inspect SECC board - Check connections from SECC board(s) to MCU (J13 and J18) - Check connection crimps and ensure wires are secured to connectors - Check CAN connection to MCU - Check Jin signal to MCU - Check for jumpers on SECC board - Replace SECC board if necessary CHARGER_ENGINE_OFFLINE Dispenser 1 High Power cabinets are not communicating with Dispenser No communication with tower for > 5 sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check power in Tower - Open up Tower and perform visual inspection - Check 24V power supplies in Tower - Check fiber optic cables - Check fiber optic transceiver(s) DISPENSER_TYPE_MISMATCH Dispenser 1 High Firmware and application configuration mismatch - Contact BTC Power for assistance - Check if error is persistent. If persistent, dial into system, and reconfigure Payment App and MCU correctly with proper firmware and settings. LEVEL_SENSOR_FAILURE Dispenser 1 High Level of cooling fluid is less than required, or Level sensor failure coolant level sensor status is low for > 100ms. - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check coolant level (SWI-HPDC- 002) - Conduct voltage test on J11 connector (SWI-HPDC-032). - Replace level sensor cable if voltage test failed (SWI-HPDC-007) NO_MCU_COMMUNICATION Dispenser 1 High Payment application is not able to communicate with controller No communication between payment application and MCU for greater then 10sec - Contact BTC power for assistance - Attempt to reflash code - Dispatch technician if reflashing does not resolve issue - Check 24 VDC input power to board - Check 232 connection between PC and MCU Board" DISPENSER_SAFETY_ERROR Dispenser 2 High (if in faulted state) /medium (if reason for shutdown) Dispenser Door is open, or safety on dispenser is lost Dispenser safety is disabled for > 50 ms - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check ground detect - Check alignment of door switches - Check continuity of door switches - Replace door switch if no continuity - Check safety circuit - Check wire connections and connectors (possible bad connections) 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 51 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS TOWER_OFFLINE Tower 2 High (if in faulted state) /medium (if reason for shutdown) Charger is not able to communicate with power cabinet tower during charging session. No communication with tower for > 5 sec - Request customer to attempt another charge session - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Communication may need to be checked - If communication is completely lost, then CHARGER_ENGINE_OFFLINE will be thrown. Follow same troubleshooting procedures as CHARGER_ENGINE_OFFLINE CUBE_OFFLINE_FAILURE Dispenser 2 High (if in faulted state) /medium (if reason for shutdown) Dispenser is not able to communicate with Power Module in power cabinet tower. No communication with power module > 5 sec TOWER_SAFETY_ERROR Tower 2 High (if in faulted state) /medium (if reason for shutdown) Tower Door Open is open, or safety on Tower is lost Tower safety is disabled for > 50 ms - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check ground detect - Check alignment of door switches (3 locations) - Check continuity of door switches (3 locations) - Replace door switch if no continuity - Check CB1 and CB2 - Close door switch and check lights of safety relay - Check wire connections and connectors (possible bad connections) CHARGER_DOOR_OPEN Dispenser 2 High (if in faulted state) /medium (if reason for shutdown) Charger door open detected Dispenser door switch status is low for > 50ms - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely If door is closed and error is still present: - Check alignment of door switch - Check continuity of door switch - Replace door switch if no continuity - Check wire connections and connectors (possible bad connections) - Initiate a charge session and check lights of safety relay DISPENSER_INTERMITTENT_SAFETY_ERROR Dispenser 3 Medium/if frequent, High Dispenser safety is getting removed which is causing reset on MCU - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Replace Dispenser MCU with updated MCU (with U29 sticker) - Check Dispenser Safety Loop 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 52 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J20 Dispenser 4 Medium Cord Temperature on J20 sensor is higher than threshold Cable temperature on J20 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J20 connector on the MCU Board - Determine thermistor wire colors at the J20 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J20 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. OVER_TEMPCORD_J22 Dispenser 4 Medium Cord Temperature on J22 sensor is higher than threshold Cable temperature on J22 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J22 connector on the MCU Board - Determine thermistor wire colors at the J22 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J22 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 53 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J20 Dispenser 4 Medium Cord Temperature on J20 sensor is higher than threshold Cable temperature on J20 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J20 connector on the MCU Board - Determine thermistor wire colors at the J20 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J20 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. OVER_TEMPCORD_J22 Dispenser 4 Medium Cord Temperature on J22 sensor is higher than threshold Cable temperature on J22 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J22 connector on the MCU Board - Determine thermistor wire colors at the J22 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J22 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 54 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J24 Dispenser 4 Medium Cord Temperature on J24 sensor is higher than threshold Cable temperature on J24 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J24 connector on the MCU Board - Determine thermistor wire colors at the J24 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J24 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. OVER_TEMPCORD_J26 Dispenser 4 Medium Cord Temperature on J26 sensor is higher than threshold Cable temperature on J26 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J26 connector on the MCU Board - Determine thermistor wire colors at the J26 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J26 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 55 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J26 Dispenser 4 Medium Cord Temperature on J26 sensor is higher than threshold Cable temperature on J26 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J26 connector on the MCU Board - Determine thermistor wire colors at the J26 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J26 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. OVER_TEMPCORD_J23 Dispenser 4 Medium Cord Temperature on J23 sensor is higher than threshold. (MCU 5.1 Board only) Cable temperature on J23 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate the J23 connector on the MCU Board - Determine thermistor wire colors at the J23 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J23 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 56 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J21 Dispenser 4 Medium Cord Temperature on J21 sensor is higher than threshold. (MCU 5.1 Board only) Cable temperature on J21 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate J21 connector on the MCU Board - Determine thermistor wire colors at the J21 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J21 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other side cable. OVER_TEMPCORD_J27 Dispenser 4 Medium Cord Temperature on J27 sensor is higher than threshold. (MCU 5.1 Board only) Cable temperature on J27 sensor is greater than 95c for > 2sec "- Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely" - Locate the J27 connector on the MCU Board - Determine thermistor wire colors at the J27 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J27 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 57 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS OVER_TEMPCORD_J25 Dispenser 4 Medium Cord Temperature on J25 sensor is higher than threshold. (MCU 5.1 Board only) Cable temperature on J25 sensor is greater than 95c for > 2sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Locate J25 connector on the MCU Board - Determine thermistor wire colors at the J25 connection - If wires are black, proceed to next step. - If wires are not black (any other color), call BTC for redispatch. - Trace the black wires from the J25 connector and determine if they go to the left or the right cable. This will determine the cable you will work on. - Take photos of the thermistor landings prior to beginning work. - Remove and replace both thermistors on the cable that was determined previously. - Ensure all thermistors are connected at the proper locations. - If the Dispenser is Dual CCS, replace the thermistors for the other cable. CHARGER_OVERVOLTAGE_ERROR Dispenser 4 Medium Over voltage fault detected on power module by Dispenser. Can be caused due to opening contactors by vehicle or charger in emergency shut down situations. Dispenser detected voltage greater than threshold for that charging session - Check calibration via TeamViewer - Check settings - Check dispenser output contactors - Check MiniPCM connections CHARGER_OVERCURRENT_ERROR Dispenser 4 Medium Charger over current fault detected on power module Dispenser detected current greater than threshold for that charging session - Check calibration via TeamViewer - Check settings - Check dispenser output contactors - Check MiniPCM connections TOWER_INTERMITTENT_SAFETY_ERROR Tower 4 Medium Tower Safety is getting removed which is causing charge session to drop to 0A and stay in that state. Tower safety loss detected during charging session - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check door switches on Tower (3 locations). Check for proper alignment and continuity. (Possible fans causing left door to open, disengaging door switch) - Check safety relay LEDs and ensure all five LEDs are illuminated. You will need to engage front door switch. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 58 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS TOWER_INTERMITTENT_SAFETY_ERROR Tower 4 Medium Tower Safety is getting removed which is causing charge session to drop to 0A and stay in that state. Tower safety loss detected during charging session - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check door switches on Tower (3 locations). Check for proper alignment and continuity. (Possible fans causing left door to open, disengaging door switch) - Check safety relay LEDs and ensure all five LEDs are illuminated. You will need to engage front door switch. DISP_ISO_CIRCUIT_FAIL Dispenser 4 Medium Charge session failed due to ISO detect ISO fail detected for greater than 50 ms during charging session - Check safety loop (MiniPCM to safety relay) - Check cable grounding - Check for any loose wires OFFSET_VOLTAGE_IDLE_ERROR Dispenser 4 Medium Charger detects voltage in idle state Charger detected voltage greater than 10VDC for 2sec before start of isolation test - Check calibration via TeamViewer - Check grounding - Replace MiniPCM TOWER_INITIATED_SHUTDOWN Tower 4 Medium "This error can be generated due to different reasons. E.g. Initiating phase -: 1. Power module is not able to turn on and unable give ready status. 2. Timeout for vehicle ready signal. Cable Check phase -: 1. Cable Check fails because charger is not able to generate requested voltage. 2. Cable check fails because charger bleed register is not able to bleed generated voltage 3. Timeout for precharge completion. Charging Phase -: 1. If vehicle opens contactor and Power module detects it before Dispenser then it initiates shutdown sequence. 2. Any fault detected on Power Module which initiates shutdown sequence, i.e., Driver error 3. Communication loss detected by power module and initiates shutdown sequence etc." Multiple faults can cause this. If shutdown started from tower and charger will not be able to receive correct fault before shutdown this error will be set. - Review logs for error history - Reattempt charging session - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check door switches (Tower and Dispenser) - Check fiber transceivers - If no issue is found, re-energize tower and call in for additional help 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 59 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS MASTER_CAN_TIMEOUT Dispenser 4 Medium Dispenser to Tower - one of the CAN fibers is broken and tower master board is not able to receive any CAN messages from dispenser while charging. No CAN message detected for 5 sec - Check fiber optic cables for TX in Dispenser and RX in Tower - Check fiber transceivers on both Tower and Dispenser MASTER_PROCESS_TIMEOUT Dispenser 4 Medium Master statemachine timeout - need to send to engineering Multiple timeouts for various stages in Tower MCU - Analyze logs and send to BTC Power engineering MASTER_STATE_MISMATCH Dispenser 4 Medium State mismatch between Tower MCU and Dispenser MCU - Analyze logs and send to BTC Power engineering COMMUNICATION_FAILED Vehicle/Dispenser 4 Medium "Multiple conditions can cause this error code. 1. Vehicle is not responding to charger. 2. SLAC failed 3. Charger is not able to complete initial communication with vehicle. 4. Vehicle not connected properly 5. Cable connector not making proper contact with vehicle due to weight/length of cable." "Vehicle communication failed. Multiple scenarios can cause this error. For CHAdeMO no response from for 6sec. For CCS no SLAC from vehicle for 30sec etc." - Dial into system and close safety in Dispenser - Recommend attempting another charging session - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check if it is CHAdeMO or CCS side - Check CAN communication - Check SECC board (if applicable) - If no issue is found, call in for additional help TIMEOUT_POWERMODULE_TURNON Tower 4 Medium If any power module is not enabled after start signal 30 sec timeout after power module turn on command is issued - Analyze logs - BTC Power will issue dispatch instructions - Check if input Tower breaker is tripped WAITING_ISOLATION_TEST_TIMEOUT Dispenser 4 Medium "- Charger is not able to complete CableCheck in time - Application side - Tower may not be sending voltage" If Isolation test is not getting completed in 60sec - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Compare metered voltage with on-screen values - Contact BTC Power for additional troubleshooting INTERLOCK_FAILURE Tower/Dispenser 4 Medium Interlock between Tower and Dispenser is lost while charging If interlock signal is removed for > 50ms while in charging. - Check interlock wire connections between Tower and Dispenser CUBE_ERROR_1 Tower 4 Medium Power module loses ready signal. Can be caused by overheating. Error detected on power module for > 5ms - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check fan operation - Check proper fan orientation (needs to be blowing outwards) 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 60 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS CUBE_NOT_READY Tower 4 Medium Ready signal on Power Module is not present Ready signal not detected for 5 ms - Check power module status - Check wiring on HV Combo Board (possible replacement) CUBE_DERR_ERROR Tower 4 Medium Power module detects Driver error (IGBT issue) Error detected on power module for > 5ms - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check HV Combo Board light - Contact BTC Power for additional troubleshooting CUBE_INIT_FAILURE Tower 4 Medium Power module fails to initialize Error detected on power module for > 5ms - Review logs for error history - Technician may be dispatched if issue cannot be solved remotely ISOLATIONTEST_TIMEOUT Dispenser/Vehicle 4 Medium Power module not able to generate voltage to complete isolation test on charger side No voltage generated during Isolation Test in 30 sec - Check logs - Check power module status WAITING_CHARGING_PERMISSION_TIMEOUT Dispenser/Vehicle 4 Medium If charger does not receive permission from vehicle to start session before timeout. Timeout on application after isolation test completed - Note vehicle model - Recommend customer to attempt charging again - Monitor vehicle types and frequency of error - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check output contactor - Check SECC connections to cable VEHICLE_CHARGE_SYSTEM_ERROR Vehicle 4 Medium Vehicle timeout - Attempt another charge session VEHICLE_JINSIGNAL_REMOVED Vehicle 4 Medium In shutdown sequence, if vehicle will not remove JIN signal in time, then charger sends this error. This is not the reason which caused charging session shutdown. This is while completing shutdown sequence. (CHAdeMO issue) - Note vehicle model - Recommend customer to attempt charging again - Monitor vehicle types and frequency of error - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 61 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS PROXIMITY_ERROR1 Vehicle 5 Low Timeout of vehicle communication. - Note vehicle model - Recommend customer to attempt charging again - Monitor vehicle types and frequency of error - Check logs on SECC Board via PUTTY - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely CHAdeMO: - Check proximity wire (1.2 - 1.6 V) with test box - Check proximity wire continuity from Pin to terminal block (possible bad cable) - Possible issue with MCU or CHAdeMO Cable CCS: - Check S3 switch impedance from Pin to terminal block - 480 ohms when the latch is pressed - 150 ohms when the latch is NOT pressed - Possible issue with SECC Board or CCS cable PROXIMITY_ERROR2 Vehicle 5 Low For CHAdeMO vehicle after initial communication the vehicle should send "vehicle ready flag" which is ChargeEnable flag and JINSignal should be raised in 8sec from D1 signal enabled. - Note vehicle model - Customer needs to make sure vehicle is plugged in correctly, turned off and in park state. - Recommend removing charger, then power cycling car (turning off then on again), and finally re- attempting charging session - If issue persists, contact BTC Power for further assistance CHAdeMO - Check continuity of all the Signal wires (possible bad CHAdeMO cable) - Possible issue with MCU Board, may need to replace PRECHARGE_TIMEOUT Dispenser 5 Low Timeout to reach precharge voltage or vehicle contactor close on CCS vehicle - Check logs and find if precharge voltage was generated or not and then find issue - Check calibration on charger - Check output contactor on dispenser GET_EVCERT_TIMEOUT PNC 5 Low Timeout while waiting for EV certificate in PNC (PlugNCharge) - Check logs and find issue. - Check certificate on charger GET_EVCERT_DECLINE PNC 5 Low Decline of EV certificate by server in PNC (PlugNCharge) - Check logs and find issue. - Check certificate on charger PNC_AUTH_NOTAPPROVED Server 5 Low PNC (PlugNCharge) authorization message declined by server - Check logs and find issue. - Check certificate on charger 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 62 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS TIMEOUT_VEHICLE_EV_CONTACTOR_CLOSE Vehicle 5 Low This is timeout after Cable Check is completed. For CHAdeMO vehicle should close contactor in 4sec after D2 signal raised by charger. - Note vehicle model - Recommend customer to attempt charging again - Monitor vehicle types and frequency of error - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check voltage calibration TIMEOUT_VEHICLE_EV_CONTACTOR_OPEN Dispenser/Vehicle 5 Low In shutdown sequence if present voltage is not dropped below 20V in 4sec then charger triggers this error. This is not reason for shutdown. None None TIMEOUT_CHARGING_CURRENT_REQUEST Vehicle 5 Low After vehicle contactor closed vehicle should send current command request in 4sec. - Note vehicle model - Recommend customer to attempt charging again - Monitor vehicle types and frequency of error - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check current calibration TOWER_NOPOWER_AVAILABLE Tower 5 Low All power modules are either occupied or in faulted state, so the Tower cannot assign any power for charge session. On initialization tower didn't have any power available to assign for charge session. - Check tower status and fault on charger - Inspect power module - Input breaker status" 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 63 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS CUBE_OVERVOLTAGE_ERROR Tower 5 Low Power module detects over voltage error - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Test with vehicle and verify issue with meter - Inspect Power module, wiring, and bus bars - Isolate each power module by disconnecting CAN1 connector on combo MCU - Check output contactors on affected modules APP_VEHICLE_RESPONSE_TIMEOUT Vehicle 5 Low Vehicle did not respond to initial handshaking 60sec timeout after plug in vehicle If frequent, then: - Check configuration and calibration of board - Check certificates on SECC - Check CCS cable connection - Check latch on CCS cable - Check SECC board for any damage" VEHICLE_TIMEOUT Vehicle 5 Low Vehicle timeout in contact authentication loop. Mostly when customer takes more time to pay or if vehicle needs time between 2 attempts. - Have customer reattempt charging session - If error persists, contact BTC Power - Connect to system remotely and execute ping using PUTTY - Check firmware version of SECC Board - Check ethernet connection to SECC Board(s) - Check power to SECC Board(s) - Check grounding of SECC Board(s) CHARGER_NOTCOMPATIBLE Dispenser 5 Low Vehicle is not compatible with charger. None None CONNLOCK_READBCK_FAILURE Dispenser 5 Low On CHAdeMO if connector lock read back is not present. - Recommend customer to attempt another charging session - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Test CHAdeMO connector with tester or vehicle - If session fails, inspect all CHAdeMO wiring inside the dispenser - Inspect connector and locking mechanism VEHICLE_CURRENT_DEVIATION_ERROR Vehicle 5 Low Charger calibration for Current is not in range and vehicle detects deviation from requested CCR. - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check current calibration 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 64 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS VEHICLE_VOLTAGE_DEVIATION_ERROR Vehicle 5 Low Charger calibration for Voltage is not in range and vehicle detects deviation. - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check voltage calibration VEHICLE_NORMAL_SHUTDOWN Vehicle 5 Low Vehicle starts shutdown normally, i.e., stop request from vehicle without any error code. None None VEHICLE_OVERTEMP_ERROR Vehicle 5 Low Over temperature error on vehicle side. None None VEHICLE_SHIFTPOSITION_ERROR Vehicle 5 Low Vehicle is not in park mode. None None VEHICLE_OVERVOLT_ERROR Vehicle 5 Low Vehicle detects over voltage if frequent then report. VEHICLE_UNDERVOLT_ERROR Vehicle 5 Low Vehicle detects under voltage if frequent then report. VEHICLE_PERMISSION_TIMEOUT Vehicle 5 Low Vehicle permission for charging after initial communication completed. if frequent then report. VEHICLE_CONTACTORCLOSE_TIMEOUT Vehicle 5 Low Vehicle Contactor not closed after cable check and precharge in time. if frequent then report. VEHICLE_CHARGEENABLE_REMOVED Vehicle 5 Low Normal shutdown from vehicle None None VEHICLE_STATUS_FAULT Vehicle 5 Low Vehicle detects status fault and sends in message. Charger starts shutdown as per that status fault. if frequent then report. VEHICLE_COMPATIBILITY_FAILED Vehicle 5 Low Vehicle is not compatible with charger. None None APP_PAYMENT_PROCESSING_TIMEOUT Application 5 Low Server or Payment controller took too long to give authorization 30 sec timeout after reading and sending message to server "- Recommend customer to try again. If second try does not work, try with another payment method - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely" 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 65 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS NORMAL_SHUTDOWN Any 5 Low Charger was not able to capture shutdown reason for good session. (Unknown shutdown reason) None None NO_START_ACCEPT Dispenser/Server 5 Low Server rejecting transaction - will mostly occur in offline sessions. Start transaction message card ID got rejected by server. - Check setting and configuration None PROXIMITY_LOST Vehicle 5 Low CCS vehicle proximity signal lost. Vehicle got unplugged. - Check logs and analyze - Check proximity cable - Check for any loose wiring or bad connections VEHICLE_BATTERY_TEMP_INHIBIT Vehicle 5 Low Vehicle battery voltage is greater than threshold None None VEHICLE_SHIFT_POSITION Vehicle 5 Low Vehicle is not in park state None None VEHICLE_CONNECTOR_LOCK_FAULT Vehicle 5 Low Vehicle is not able to lock connector None None VEHICLE_RESS_MALFUNCTION Vehicle 5 Low Vehicle charging system malfunction None - Check current calibration VEHICLE_CHARGING_CURRENT_DIFFERENTIAL Vehicle/Dispenser 5 Low Vehicle issue or charger calibration - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Check voltage calibration VEHICLE_CHARGING_VOLTAGE_RANGE_ERROR Vehicle/Dispenser 5 Low Vehicle issue or charger calibration - Review logs for error history - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely None VEHICLE_CHARGING_SYSTEM_INCOMPATIBILITY Vehicle 5 Low Charger compatibility error None None VEHICLE_NO_DATA_ERROR Vehicle 5 Low No charge parameters from vehicle None None VEHICLE_CHARGER_INTERNAL_ERROR Vehicle 5 Low Vehicle internal error None - Check CCS latch, replace latch if broken - If error persists, CCS cable may need to be replaced 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 66 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS VEHICLE_PILOT_FAILURE Vehicle 5 Low CCS vehicle pilot signal changed from StateC to StateB. Pilot signal failure. - Note vehicle model - May need to adjust CCS cable while plugged in to make proper contact with vehicle socket (prevalent in Chevrolet Bolt) - If issue is persistent, contact BTC Power for further assistance. - Inspect tower for any visible issues - Isolate each power module by disconnecting CAN1 connector on combo MCU - Check output contactors on affected modules VEHICLE_PROXCAN_TIMEOUT Vehicle 5 Low Communication lost in between session If communication lost in between charging session for > 1sec - Check logs and find issue - Check communication cable and board VEHICLE_PROTOCOL_MISMATCH_ERROR Vehicle 5 Low Vehicle protocol number is not supported on charger If charger protocol is not matching with vehicle protocol None None AUTH_NOT_APPROVED Payment terminal / User 5 Low Other payment fails (Non-Nayax and NFC) - Recommend trying payment again. If second try does not work, try with another payment method - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely None NFC_AUTH_NOTAPPROVED Payment terminal / User 5 Low NFC Payment failed. Only UIC reader - Recommend trying payment again. If second try does not work, try with another payment method - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely None POS_AUTH_NOTAPPROVED Payment terminal / User 5 Low Nayax device payment not approved. - Recommend trying payment again. If second try does not work, try with another payment method - Nayax: Confirm correct firmware and UI version on the device - If issue is persistent, contact BTC Power for further assistance - Technician may be dispatched if issue cannot be solved remotely - Replace card reader 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 67 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS PAYMENTAPP_COMM_FAILURE Dispenser 5 Low Communication between payment application and MCU lost during session PAYMENT_AUTH_REJECTED Server 5 Low Server rejected payment authorization request. None None APP_PAYMENT_SCREEN_TIMEOUT Application 6 Info No payment presented on payment screen 90 sec timeout on present payment screen None None APP_OTHER_CONNECTOR_OCCUPIED Application/Dispenser 6 Info Charging in session on another connector. Charging system can only use one connector at a time. None None ERROR_CODE_XX Tower/Dispenser 6 Info Future reference. STOPBUTTON_PRESSED User 6 Info Customer press stop button None None BATTERY_FULL Dispenser 6 Info 100% SOC on vehicle None None MAX_CHARGING_TIME_COMPLETED Dispenser 6 Info If maximum charging time is enabled on the charger, the session shutdown was due to this time limit. None None MAX_SOC_LIMIT Dispenser 6 Info If charger has an SOC limit enabled, the session shutdown was due to the set limit. None None USER_STOP_SCREEN User 6 Info User pressed stop button on screen None None USER_STOP_BUTTON User 6 Info User pressed hardware stop button None None SERVER_SOFT_RESET Server 6 Info Server resetting charger payment application. None None SERVER_HARD_RESET Server 6 Info Server resetting charger payment controller (PC). None None SERVER_SET_UNAVAILABLE Server 6 Info Server set unavailable for connector or for complete charger. Usually thrown when the charger taken offline for servicing on a ticket. APP_MAX_CHARGING_TIME Dispenser 6 Info If Max charging time enabled and charger reach to max limit. None None 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 68 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D OPERATION ERROR CODE ERROR SOURCE LEVEL DESCRIPTION CONDITION REMOTE ACTIONS FIELD TROUBLESHOOTING STEPS TIMEOUT_XX Tower/Dispenser 6 Info USER_STOP_REMOTE User/server 6 Info Charging session stopped by user using mobile application or server. None None USER_PAYMENT_CANCEL User 6 Info User pressed CANCEL button on present payment screen before pay. None None USER_PRICE_CANCEL User 6 Info User press cancel button on show price screen. None None UNKNOWN Payment App 6 Info Only happens on startup, should clear when system is on. No action required. None None CUBE_OVERTEMP_ERROR Tower 3 Medium/if frequent, High Power module had Over temperature fault Analysis logs and check if any action needed Check power module fans and replace if needed PNC_TLS_HANDSHAKE_FAILED Payment App/SECC 4 Medium Vehicle and charger failed TLS handshake due to certificate mismatch CPO: Check if certificates are updated on charger or not. Check expiry dates Vendor: Check if charger have correct certificates and configuration to support PnC VEHICLE_WAITING_FOR_PAYMENT_TIMEOUT Vehicle 5 Low Vehicle timed out in CA state Too long to complete payment APP_INITATING_SCREEN_TIMEOUT Dispenser 4 Medium Charger timed out on initiating screen due to no isolation test and Dispenser taking too much time to response Analysis logs and check if any action needed POWER_LOSS Dispenser 4 Medium Dispenser lost power while in charging vehicle. Fault will be sent after restoring power so it will be reported after dispatch. Loss of power Check AC input, Fuse, Power supplies and restore power. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 69 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE 10. Maintenance DANGER All servicing must be performed ONLY by qualified personnel. Do not attempt to service the 360kW High Power DC Charger yourself. Make sure to turn off the power to the charger before performing any maintenance activity. Maintenance Precautions Each of the capacitors in this device have a high voltage for a time after shutting off the input power supply. Must allow five (5) minutes after powering down before servicing internal components. Maintenance Items Perform periodic maintenance of both Power Unit / Tower and Dispenser units. Outlined below are the mandatory maintenance works for the Power Unit / Tower unit that must be carried out in the prescribed interval. SCOPE MAINTENANCE WORK INTERVAL External Maintenance • Check the DC Power Unit / Tower for mechanical damage, corrosion, restriction of IP degree of protection, abnormal odor etc. • Check branding labels and signages are in good and legible condition • Clean using water or neutral pH solution Annual Internal Maintenance • Check door conditions with no gaps around door and gasket • Vacuum clean internal components from dust • Clean and check air intake and exhaust vents for debris and foreign materials • Replace air filters every two (2) years or as necessary • Check if power modules are fully seated • Inspect AC/DC terminations and look for signs of arcing and heat-stress on cables and bussing Annual 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 70 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE SCOPE MAINTENANCE WORK INTERVAL Internal Maintenance • Check all signal wiring/cabling for any damage • Check all cables and wires if secured • Tighten all high voltage terminations to its specifications Annual Performance Testing • Measure Phase to Phase and Phase to Ground Voltages on the terminal block at the main AC input o Acceptable range: ± 10% of nominal value • Perform Interlock Testing Annual Outlined below are the mandatory maintenance works for the Dispenser unit that must be carried out in the prescribed interval. SCOPE MAINTENANCE WORK INTERVAL External Maintenance • Check the Dispenser for mechanical damage, corrosion, restriction of IP degree of protection, abnormal odor etc. • Check branding labels and signages are in good and legible condition • Clean using water or neutral pH solution • Clean HMI with water only • Clean and check all cables, connectors, and holsters for any damage • Check if cables are mounted properly Annual Internal Maintenance • Check door conditions with no gaps around door and gasket • Vacuum clean internal components from dust • Clean and check air intake and exhaust vents for debris and foreign materials • Replace air filters every two (2) years or as necessary • Check if all accessible connections are secured (by gently pulling the cables/wires) • Check if all boards are firmly mounted and no dangling cables/wires • Check for signs of heating particularly on high current conductors • Tighten all high current connections to its specifications 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 71 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE SCOPE MAINTENANCE WORK INTERVAL Internal Maintenance • Check cooling system conditions o Check all cooling fittings for leaks o Check condenser for any bent or clogged fins o Clean cooling fins if needed (extra care not to bend) o Straighten cooling fins if bent using a fin comb o Ensure cooling fins are secured and not loose o Check coolant level and refill if necessary Annual Performance Testing • Measure Incoming AC Voltage • Perform Interlock Testing • Check if HMI & Nayax touch screen and pushbutton are operating properly • Perform testing on charging cable using Comemso Annual Replacement of Fixed-Life Components To prevent the device from failure due to worn out components, it is necessary to replace the components before they reach the end of their lifespan. Use the following replacement intervals as a guideline for the estimate of the total running time. Please contact a BTC Power representative for further assistance when you replace the parts. • Charging Cables: Approximately three (3) years • Intake and exhaust filters: Approximately two (2) years • Coolant: Every five (5) years NOTE Please keep in mind that the replacement interval of each part can vary depending on, for example, the usage environment of the device. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 72 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE Door Switch Feature To cheat the charger’s interlock, pull the door switch for permanent contact function. NOTE: Pull the door switch carefully and slowly to avoid damages. CAUTION This procedure will enable the system to be energized with the door open — proceed and operate with caution. 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 73 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE Recommended Parts List ITEM PART NUMBER PART DESCRIPTION 1 190-0551-01 EVPC-360-480-II-00 Harness 2 110-0295-01 XBU Tower 3 170-0470-01 Power Line Filters, 3PHASE 400A 4 170-0528-01 Contactor CONT ACNO 225A 600V 24VDC AUXNO M10 CHA 5 201-0225-01 30kW Power Module 6 157-0057-01 DC Output Fuse, 400A 1000V 7 170-0142-01 DC Contactor, 350A 1500 VDC 8 150-0316-01 10 Ohms 160W Chassis Mount Resistor 9 170-0210-01 CAN / Optic Fiber - Repeater - Extender Bus Line 10 170-0067-01 Latch Assembly 11 170-0262-01 Relay Contactor 3PST 40A 24V 12 170-0446-01 SPD Device 13 170-0556-01 Endcap Kit, Series G, 3-pole 14 110-0277-01 MCU 360 15 170-0344-01 Ferrite Clamp on Cores 16 157-0089-01 Fuse Cartridge 8A 600VAC/300VDC SLO 17 110-0289-01 Fan Distribution Board 18 157-0069-01 Fuse SL CC 5.6A 600VAC 10.33x38.1 19 157-0099-01 Fuse SL CC 8A 600VAC 10x38 20 157-0100-01 Fuse SL CC 15A 600VAC 10x38 21 157-0067-01 Fuse SL CC 10A 600VAC 10x38 w/ holder 22 170-0645-01 Thermostat 23 170-0311-01 Switching Power Supplies 600W 24V 25A (Alternate) 24 170-0741-01 Switching Power Supplies 600W 24V 25A, Wire term, Type A 25 140-0181-01 Transformer 26 202-0101-01 Gen4 Tower GFCI/Breaker Assembly 27 202-0102-01 Gen4 Tower Filter Kit 28 202-0103-01 Gen4 Tower Hardware Kit 29 202-0119-01 Gen4 Tower Contactor Matrix Service Kit 30 202-0115-01 480W Switching Power Supplies 24V 20A Service Kit 31 202-0114-01 360KW Door Lock Service Kit 32 202-0112-01 DC Fans DC Fan, 172x51mm, 24VDC, Service Kit 33 202-0110-01 AC Input Cables Service Kit 34 202-0111-01 DC Output Cables Service Kit 35 202-0109-01 Interlock Pushbutton Cherry Service Kit 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 74 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE Dispenser ITEM PART NUMBER PART DESCRIPTION 1 190-1390-01 EVDSP-350-EA-00 Harness 2 170-0210-01 Fiber-Optic Transceiver 3 157-0052-01 Fuse Holder 4 170-0709-01 SSD 5 170-0276-01 VPOS Touch 4G US Marshall Black 6 170-0657-01 Waterproof Voice Speaker 7 190-0146-01 VPOS Touch Cable - Marshall 8 190-0122-01 Ethernet Cable 9 170-0241-01 USB Cable Card Reader (RFID CABLE) 10 158-0099-01 Standoff Insulator 11 170-0681-01 PC with Audio IC 12 170-0571-01 Dual Ethernet LTE or LTE-M/NB-lot Commercial Router 13 170-0716-01 480W Switching Power Supplies 24V 20A 14 170-0717-01 150W Switching Power Supplies 12V 10A 15 170-0319-01 Antenna 16 170-0698-01 DC Axial Fan 17 170-0735-01 Power Meter 18 170-0233-01 RFID Reader 19 190-0078-01 750lb Paracord/Parachute Cord 20 170-0732-01 Ohmite Shunt Resistor 600A 60mV 21 170-0720-01 Surge Protection device 22 190-0114-01 Cool Cable Coolant 23 140-0162-01 LEM Current Transducer 24 170-0447-01 Push Buttons 25 170-0726-01 LED Light Pipe 26 157-0052-01 Fuse Holder Blok 30A 600V 2 Pole 27 157-0095-01 Fuse SL CC 1.5A 600VAC/300VDC 10.3x38.1 w/ Holder 28 157-0096-01 Fuse SL CC 0.5A 600VAC/300VDC 10.3x38.1 w/ Holder 29 170-0718-01 GFCI 30 170-0719-01 Breaker 31 130-2097-01 Upper Intake Filter 32 130-2095-01 Exhaust Filter 33 170-0733-01 DC Contactors 34 202-0097-01 SECC Service Kit 35 202-0099-01 Dold Kit 36 202-0098-01 Display Service Kit 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 75 of 89 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D MAINTENANCE Recommended Parts List (continuation) Dispenser ITEM PART NUMBER PART DESCRIPTION 37 202-0095-01 MCU 6.1 Service Kit 38 202-0096-01 Reset Board Service Kit 39 202-0100-01 Prepped HPC500 Cable (Gen4 EA Dispenser) 40 202-0104-01 Cooling Unit Assembly FCC INFORMATION The 360 kW High Power DC Charger complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1) The charger may not cause harmful interference, and 2) The charger must accept any interference received, including interference that may cause undesired operation. CAUTION Changes or modifications to this product by other than an authorized service facility could void warranty, UL, and FCC compliance. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 76 of 89 PRODUCT DISPOSAL 11. Product Disposal BTCPower Inc. carefully considers environmental impacts of our products in every stage of the product life cycle – from design, to manufacturing, to usage, and its disposal. Proper disposal of our product and parts should be observed to reduce environmental impact. Recyclable parts should be used as suitable. Hazardous waste should be disposed through safe and responsible methods. The disposal of this charger must comply with the national and regional laws and regulations. Dispose the unit in accordance with the applicable environmental regulations of your country. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 77 of 89 APPENDIX 12. Appendix 12.1. Component Information a) CCS1 High-Power Liquid Cooled Coupler (500A Rated) Part Details Part Number: 202-0100-01 Manufacturer: Huber + Suhner Standard Position of Connector Cable Length or Dimension A: 17.7 ft This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 78 of 89 APPENDIX b) Cooling Unit System Part Details Part Number: 190-1057-01 Manufacturer: Huber + Suhner c) Cool Cable Coolant Part Details (Refer to SDS document 0000840189) Part Number: 190-0114-01 Manufacturer: Huber + Suhner Description: • Non-conducting fully synthetic oil • Readily biodegradable • High dielectrical strength • 5 years shelf life • Non-hazardous • Excellent resistance to high and low temperatures • Higher flashpoint and firepoint than conventional mineral-based non-conducting oil: reduces fire risk *Application Note from supplier on page 74 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 79 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 80 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 81 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 82 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 83 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 84 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 85 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 86 of 89 APPENDIX This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 87 of 89 APPENDIX 12.2. Cooling Unit System Overview a) Main Parts b) Fill Level of Cooling Unit Figure 1 Figure 2 This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 88 of 89 APPENDIX Case 1: Tank is prefilled (standard at delivery) • Tank is prefilled to operate one cable with a maximal total length of 8m. Coolant level before connecting the cable is visible in the venting tube (refer to figure 1, number 2). • Starting up the cooling system for 5min. • Check: Coolant level must be as shown in figure 2. • If coolant level is below 100mm, refill coolant according to the instruction case 2. Case 2: Refill coolant to have the right amount of coolant in cooling system • General amount of coolant is 1.1dl per meter cable. Refilling Coolant in Cooling Unit: • Open cap no.1 and no.2 (figure 1, no.1 and no.2) • Use a funnel to avoid spillage. Connect the funnel to tube no.1 (refer to figure 1, no. 1). • Tube no.1 (figure 1, no.1) => fill in coolant • Tube no.2 (figure 1, no.2) => venting hole • Coolant level must be minimum 100mm and maximum 150mm according to the viewing pipe (refer to figure 2). • Close cap no.1 and no.2 (refer to figure 1) • Start up the cooling system for 5min. • Check: Coolant level must be as shown in figure 2. If coolant level is below 100mm, refill according to instruction in case 2. This document is a Property of BTCPower Inc. and shall not be copied, reproduced, or used as the basis for sale or manufacture of apparatus without written permission. 23-Sep-22 Rev D 360kW High Power DC Charger INSTALLATION AND USER’S MANUAL Page 89 of 89 REVISION HISTORY REVISION HISTORY Revision Date Description Originator 0 21-Apr-22 Initial Release Rosh Dihayco A 06-Jun-22 • Added Dispenser MCU Dipswitch settings • Updated error codes • Updated Dispenser DC Input Terminal Lug information • Updated Tower images, renderings, and drawings • Change location of label for Tower – Page 12 Rosh Dihayco/ Bryan Bascon B 15-Aug-22 • Page 20 – Adjusted bolt quantity to “10 or 16 (Depending on # of Dispensers being installed)” • Page 28 – Distinguished different quantities of bolts required for both Tower and Dispenser N. Kim C 20-Sep-22 • Page 29 – Updated drawings to include dimensions between the mounting holes and added language on requiring mounting the front holes and being able to choose from either pair of the rear mounting holes for the Tower footer. N. Kim D 23-Sep-22 • Added fiber-optic and interlock cable routing information on page 40. N. Kim ORANGE COUNTY FiRE AUTHORi Plan Submittal Criteria COMMERCIAL projects, MULTIFAMILY RESIDENTIAL pro and RESIDENTIAL TRACT d I CITY OF SANTA ANA Planning and Building Agency Y oFtOR PfR CF INSTRUCTIONS: eve opments • Fill in the project/business address and provide a brief description of the scope of work and type of bus nMa Ater I : • Answer questions 1 through 10. read and initial items 11 and 12, then complete and sign the certificati n4 s (f1 : at wit tom: • If you answer: - "YES" to any part of questions 1 through 10, submit the type of plan indicated in italics to OCFA. • In some cases, other plan types not indicated herein may also be necessary depending on specific conditions or operations. • Visit www.ocfa.org for submittal information and locations. If you need assistance in filling out this form or have questions regarding requirements for review, please contact OCFA at 714-573-6108 or visit us at 1 Fire Authority Road, Irvine, CA 92602. Address ness S 1 Construction of a new building, a new story, or increase the footprint of an existing buildin rbs, or drive aisles? Addition, relocation, or modification of fire hydrants or fences/gates?hConstruoctiondwithin 300 feet of an active or proposed oil well? Fire Maser-P/an (PR145r 2. f' pertit is adjacent to a wildland area or non -irrigated native vegetation? 7/V .41asIer Plan (PR14 S); a /'ue/ :tlodilicutioa Plan ilia, also he required. (PR120, 1'R124) 3. O Lo ated in or < 100' from a Division of Oil, Gas, and Geothermal Resources (DOGGR) field boundary, < 300' from n oil/gas seep, or < 1000' from a landfill? Alelhane Work Plan rPRl70) 4. O I allation/modification/repair of underground piping, backflow preventers, or fire department connections serving rivate fire hydrant/sprinkler/standpipe systems? Un11elgroll1ld Plan. (PR470, PR475) 5. O Drinking/dining/recreation/meetings/training/religious functions or other gatherings in a room > 750 sq.ft. (> 1,000 sq.ft. for training/adultedu cation) or > 49 people? Healthcare/outpatient services for > 5 people who may be unable to immediately evacuate without assistance? Education for children (academic tutoring for ages 5+ is exempt unless classified as an E occupancy by the Building Official)? Adult/child daycare? 24-hour care/supervision? Incarceration or restraint? Hotel/apartment or residential facility with 3+ units and 3+ stories (3-story townhouseslrowhouses We.ere an independent direct exit to grade is provided for dwelling are exempt)? Congregate housing/dormitories ith 17+ people? High-rise structure (55+ feet to highest occupied floor level)? ..fir hirr r ,rr,r,1 Pla,r iPR_00-PR',vs) 6. O Installation/modification of locks delaying or preventing occupants from leaving a space or requiring use of a card, tton, or similar action to open a door in the direction of exit travel? ,-t/chilec•lulz 1, Sp,-inkler, and or- t/rill,, plrin delrending on The nceupanct� cull/ 11pe ojde1,ic•e, ill s1(l/lerl (PR "00-PR?,vo, PR42(1-PR425, PRi00-PRi 0) 7 Installation/modification/use of spray booths; dust collection; dry cleaning; industrial ovens/drying equipment; industrial/commercial refrigeration systems, compressed gasses; tanks for cryogenic or flammable/combustible liquids; vapor recovery; smoke control; battery back-up/charging systems (> 50 gal. electrolyte, > 1,000 lb. lithium i ); welding/brazing/soldering, open flame torches, cutting/grinding; or other similar operations? .Sjrecial Equipment Platt (PR315, PR340-PR382) 8 O Storage/use/research with flammable/combustible liquids or other chemicals? Motor vehicle/aircraft Fcommercial ntenance/repair? Cabinetry/woodworking/finishing facility? Chenr Class & Jloor plan (/till ur-c•hilectural /)lull it cupancy):Special F_yuiprn(•ruPlus% nry henecess-arr_ 1PR 315_PR3(0. PR232-PR240) 9. age or merchandizing areas in excess of 500 sq. ft. where items are located higher than 12' (6' for high -hazard modities, plastic, rubber, foam, etc.)? High -piled Storage Plan (PR330) 10.0king under a Type I commercial hood; installation or modification of a fire extinguishing system located in a Cooking hood? //ur tl c4' Uric! Frtin�rri.vhit{g S►slem, nul,jttsl (hc /rood nrec hcrnic u/ p/urr. (PR335) Initial each of the following two items indicating that you have read and understand the statement: 11. "Sprinklers/Alarms: Consult Building/Fire Codes and ordinances to determine sprinkler/alarm requirements; if a system is required, plans shall be submitted for OCFA review. Existing buildings undergoing remodel must be evaluated by a licensed contractor to determine if modification is needed; if so, contractor shall submit plans prior to making modifications. 12. Fire Hazard Severity Zone: Consult maps available at building department or on OCFA website to determine if your site is located in a FHSZ. Buildings in a FHSZ may be subject to special construction requirements detailed in CBC Chapter 7A or CRC R327— t.1, the building department will determine specific requirements. I certify under p�talty of perj!�y under the laws of the State of California that the above is true: Print Name CJ Phone Number (�6 2 Date Butldini; Department. // von hurt vcll/red that all a/'the questions have heel/ allslvere41 aralel)' as NO , and the proper does our nnc�rnisr' require OC1.q r•eviely ul sprillkler ur• alarm plans"', then qua rrral' accept this signed filr•nt as a u•rillell reh"Isc tlult UC'h: t review is nut reyuire'd..S7roaA1 ruu still require that the applicant have plans approved bl• OCFA. please initial here a• attach an OCFA re%rr�r/ form trial have Me applicant submu the Jornr along lril/t the apprupriale plans and firs_ jor oCFA review. 10-08-14 EE