DOC: CA10-CL20-UM_X_28MAR11.

doc

1 of 43

Table of Contents:

Read Me First 3 Whats in the box? 4 Understanding the Label 4 Frequently Asked Questions 5 Functional Description of the Charger Features 6 Output Characteristics 7 CONNECTIONS TO THE CHARGER DC Output 8 Universal AC Input 9 Fan Connection (Air-Cooled) 10 CAN Communications 11 Ground Lug 12 COOLING Air-Cooled Chargers 12 Liquid-Cooled Chargers 12 INTERNAL MODULE DESCRIPTION Single Unit Charger 13 Manual Operation 13 Staged Charging 13 BMS Controlled 13 Paralleling of Chargers 13 CA10x03 and CL20x03 PRODUCT FAMILY Air-Cooled 15 Liquid-Cooled 18 CABLE DIAGRAMS AC Input Cable 21 DC Output Cable 21 Pump/LED Cable 22 Communications Cable 22 Block Diagram 23 Specifications 24

AC Input 25 Controls Input 25 DC Output (208VAC input or above) 25 Low Voltage Output Range 1 units (CA10L03, CL20L03) 25 High Voltage Output Range 2 units (CA10H03, CL20H03) 25 Power Limits 26 Battery Voltage Compensation 26 Output General 27 Protection Features 27 LED Indicator Function 27 Environmental 28 Computer Interface 28 Software Install 29 Installing the Lawicel CAN-USB Adapter 29 Installing the PEAK PCAN USBCAN Adapter 34 Installing the Current Ways VIP Control Software GUI Setup and Connections 34 Current Ways VIP Control Software GUI Operation with Charger 39 Stage Charging Setup 40 Battery Management System Interface 41 Updating the Internal Charger Control Firmware 41 SAE J1772 Control of Charger 41 MECHANICAL OUTLINE DRAWINGS Air-Cooled Charger 42 Liquid-Cooled Charger 43

This manual is copyright and wholly owned by Current Ways Inc. and is for the exclusive use of its customers. Any other use of this manual must be by expressed written permission of Current Ways Inc. Current Ways Inc. 10221 Buena Vista Ave. Santee, CA 92017 USA 619-596-3984 www.CurrentWays.com
Current Ways Inc. reserves the right to alter product offerings and specifications at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. Copyright 2011 Current Ways, Inc. All rights reserved. PLUGIN TO THE POWER is a U.S. registered trademark/service mark, and an EU registered logo mark of Current Ways, Inc. All other products or services mentioned are the trademarks, service marks, registered trademarks or registered service marks of their respective owners. Current Ways has several patent applications filed.

2 of 43

SECTION 1 - READ ME FIRST: Congratulations and Thank you for your purchase of the Current Ways Inc. BC-Series of IP67 fully sealed, output isolated electric vehicle battery charger. The Current Ways design and production team has spared no effort to make this battery charger system a feature packed worldclass product with high performance and high efficiency at a competitive price. To fully utilize the features and to operate the unit safely, please read this entire manual before installing or applying power to the charger.

WARNING: TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH. DO NOT REMOVE ANY OF THE COVERS ON THE CHARGER. DOING SO WILL EXPOSE POTENTIALLY LETHAL VOLTAGES AND VOID THE WARRANTY. THERE ARE NO FIELD SERVICEABLE PARTS INSIDE. END USER IS REQUIRED TO INSTALL FUSES ON THE DC OUTPUT CABLE, BOTH POSITIVE AND NEGATIVE, AS CLOSE TO THE BATTERIES AS POSSIBLE. REFER TO THE USER MANUAL FOR RECOMMENDED FUSE SIZES. TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! ALTHOUGH THE CONNECTOR SYSTEM UTILIZED IS CONSIDERED FINGER SAFE, THE USER MUST DISCONNECT THE BATTERY BEFORE TOUCHING OR REMOVING THE BATTERY FUSES OR REMOVING THE DC OUTPUT CABLE FROM THE CHARGER. FAILING TO HEED THIS WARNING MAY RESULT IN INJURY OR DEATH. IMPROPER SETUP AND USE OF THIS CHARGER CAN RESULT IN DAMAGE TO THE BATTERY AND OTHER ASSOCIATED SYSTEM. CURRENT WAYS WILL NOT BE RESPONSIBLE FOR IMPROPER USE OF THIS DEVICE.

3 of 43

The Current Ways BC-Series of high voltage traction battery chargers are designed with safety first in mind. Lethal voltages exist on the input and output connectors, cables, and batteries in typical systems. To fully utilize all the safety and operational features of the charger, please carefully read all the operation instructions described in this manual, and retain this manual for future reference. Updated manuals and other related documents can always be downloaded from the Current Ways website www.CurrentWays.com.
WHATS IN THE BOX: Besides the charger, cables that were ordered with the charger, a CD ROM with this manual and the VIP Control Software for operation of the charger, and other options will be contained within the shipping container.

UNDERSTANDING THE LABEL: The charger has a detailed label with the various particulars for the model printed upon it. A brief guide to reading this label follows:

4 of 43

Frequently Asked Questions: 1. The charger will operate out of the box only with one industry standard BMS protocol; all other modes of operation require setup and/or control by the Current Ways VIP Control Software GUI program supplied. Read this manual in its entirety before operating or applying power to the charger. 2. Verify your batterys charging requirements and setup the charger appropriately. Never exceed your batterys maximum charging voltage. Current Ways is not responsible for any battery or system damage due to improper use of the charger. 3. All connectors must be present for the charger to operate, as there are interlocks in the AC Input, DC Output, CAN Communications, and Fan/Pump/LED connectors. 4. The charger can be mounted in any plane as long as fresh cooling air can enter and exit (60 CFM) from the air cooled model, and sufficient cooling liquid (4 liters/min) is circulated through the liquid cooled model. 5. The charger exterior will become warm during operation. In the case of a failure in the coolant system, the charger will become very hot and could possibly cause burns if touched. Keep hands and materials away from the charger when in operation 6. The charger does not have internal DC output fuses. Proper installation of appropriate output fuses is required for safe operation. 7. If you are unsure of any point of the installation and use, please contact the factory for assistance before installing or operating this charger. 8. Do not remove any covers or panels on the unit under any circumstances. There are no user serviceable parts inside. Opening the unit will expose potentially lethal voltages and will also result in damaging the IP67 seals voiding the warranty. 9. Do not connect the unit to AC mains until a thorough inspection of the battery and control connections has been done. Battery voltages are lethal and Current Ways will not be responsible for any negligent use or damage. 10. Never operate the unit without appropriate grounding / earthing connections. 11. Use a GFI device in the AC mains to the charger. 12. Never overload the AC mains connection as this is a fire danger. 13. Always use appropriately sized AC mains conductors to the charger to prevent poor operation and fire danger. 14. Disconnect the charger from the AC mains when not in use. 15. If you are ever unsure of anything regarding the proper use of the charger, consult the factory before making a potentially damaging error!

5 of 43

SECTION 2 Functional Descriptions of Charger Features

ENCLOSURE: The case of the BC-Series battery charger is sealed against the elements and is rated for IP67 operation; it is resistant to immersion in water to one meter for one half hour, so the unit can be mounted in relatively unprotected areas of the vehicle. All case components, connectors, fans, hardware, etc. are rated for temporary water immersion without water ingress to the electronics inside. The internal design is extremely shock and vibration resistant, with all components of substantial mass or thermal characteristics being fully supported and thermally connected to either the air or liquid cooled heatsinks, depending on the model. The CA10 model is air cooled (the fans are electrically isolated and immersable), and the CL20 model is liquid cooled (use of an aluminum compatible 50/50 water/glycol coolant mix is required).

MOUNTING: Six M6-1 machine threaded bosses are installed on the charger for mounting the unit to a flat surface within the vehicle or externally. For the air cooled versions, these bosses are on the electronics module cover:

6 of 43

For the liquid cooled unit, the six M6 bosses are installed on the baseplate of the heatsink:

The length of the M6-1xN screws should be chosen so that between 4 and 6 mm of the screw tip protrudes into the mounting surface of the charger. An optionally available mounting plate can be attached using these bosses and to create a flanged style mounting system if desired. See the product family section in this manual for more detailed mounting drawings. Note: Do not exceed the recommended screw protrusion depth into the mounting bosses. Exceeding the recommended depth could cause breakthrough in the bosses that would compromise the watertight rating of the charger, or could potentially cause damage to the mounting point. OUTPUT CHARACTERISTICS: The BC-Series battery charger is capable of 3kW of constant output power in two voltage ranges; either 112-225V (Low range) or 225-450V (High range). The output range is selected at order time by indicating L or H in the 5th position of the model number - CA10L03 and CL20L03 models are internally set for the Low range, and the CA10H03 and CL20H03 are internally set for the High range. Output current below 112V on the low range is automatically restricted to 27A maximum down to near zero volts of output, and on the high range below 225V the current is automatically restricted to 13.5A maximum also down to near zero volts of output.

7 of 43

CONNECTIONS TO THE CHARGER; DC OUTPUT: DC output is via a 2 pin Tyco 280 automotive style sealed interlocked touchproof connector on the I/O panel. The separately ordered DC output cables P/N 056156 have shielded conductors (at chassis potential), safety orange in color. The DC output cable must be plugged into the charger for operation. Interlocks built into the DC output cable connector and the two circular control connectors require that all be present for the charger to operate.

DC Cable Wiring Breakout; Black BATTERY NEGATIVE, Red BATTERY POSITIVE, Sheilds CHASSIS / EARTH Use of a disconnecting contactor to the battery is highly recommended, so that the charger is isolated from the battery during drive time. The DC output connector is interlocked, so upon removal, the power output stage of the charger is disabled. Bleed down of the internal output storage capacitors upon removal of the connector from the chassis meets UL2202 specifications. External DC fuses must be used in each lead to the storage battery these fuses must be located as close to the battery as possible to protect battery and charger in case of a short in the DC output cabling or a reversed polarity connection. A reverse polarity diode is installed internally to the charger, and will cause the external output fuses to blow should the charger be connected reverse polarity. There are no internal output fuses within the charger. Fuses should be rated for DC operation at 600V - type KLKD is highly recommended, but others are available with similar ratings. Amperage ratings of 30A for the low voltage range unit and 15A for the high voltage range unit are recommended. If paralleled chargers are used, it is highly recommended that each DC output cable be used with a set of fuses at the battery, as shown in the illustration below:

8 of 43

Typical Output Fuse Wiring with Three Paralleled Chargers CONNECTIONS TO THE CHARGER; UNIVERSAL AC INPUT: AC input is via a 3 pin Tyco 280 automotive style sealed touchproof connector on the I/O panel. The separately ordered AC input cable P/N 056155 is shielded (chassis connected) and safety orange in color. Standard line colors are marked on the cable; black for line hot, white for line neutral or second hot, and green for earth/chassis. The user must connect an appropriate AC plug to the cable. The charger has internal 20A input fuses on both sides of the line, and these fuses will not blow during normal operation, and are present to protect against some sort of catastrophic internal failure. These fuses are NOT field replaceable. If the fuses clear, the charger must be returned to factory for repair

AC Wiring Breakout; Black LINE, 2/White NEUTRAL/LINE, 1/Green EARTH, Sheild CHASSIS / EARTH The AC input voltage range is nominally 100 to 240VAC single phase, 50-60 Hz. The AC input module is power factor corrected (PFC) to present a minimum of harmonic energy to the power source for lowest noise and lowest interference with nearby electrical equipment and the best power efficiency. The PFC function is extremely good, with total harmonic distortion typically less than 3%, and power factor typically greater than 0.99.

9 of 43

Input current is automatically limited to 12A at power up and when the input voltage is below approximately 150VAC; this is so that the unit can be used with a standard 115VAC 60Hz 15A wall socket. Output power will be automatically controlled to limit the input current to this level. The maximum output power that is typically available when operating on nominal 120VAC lines is between 1000 and 1200W. A brown-out condition, where the line dips below 100VAC will result in the charger reducing its power to keep the current at or below 12A. An automatic fault reset will occur every 30 minutes of operation to correct for any line (or load) abnormalities that cause a power output decrease such as this. The user can change the below 150VAC input setting of 12A to a maximum of 16A when a 20A 115VAC nominal line connector is available. Doing this will allow higher output from a nominal 120VAC 20A outlet of between 1300 and 1500W. This change is accomplished by selecting a setting option on the available VIP Control program GUI. This must only be done if the outlet is rated for and has circuit breaker protection for 20A. When the AC input voltage is above approximately 150V, the input current is automatically restricted to 16A, so the full power benefit of a nominal 208 or 230VAC 20A source can be used. The full 3kW of output power is available when the AC line is above 208VAC. Below that, the unit will automatically reduce output power slightly to maintain the input current to 16A (depending on line voltage). In the case of a fault, a brown out or a black out condition that causes the charger to disable its output, the charger will attempt to restart every 30 minutes. This automatic timed retry applies to any fault; output, input, thermal, etc. On the occurrence of a fault, the charger will reduce power or disable its output, wait the 30 minute interval, and try again. If the causal fault has been cleared, charging at the original parameters will resume. This feature may prevent a minor fault event which causes the charger to shut down and potentially leaving the user stranded with a discharged battery, by attempting to restart the charge cycle. CONNECTIONS TO THE CHARGER; FAN CONNECTOR (AIR COOLED): The connector panel houses a 5 pin female contact connector for the function of +12V out to fans (or cooling liquid pump control), external status indicating LED, and interlock function. Current Ways cables must be used to preserve the warranty. Please consult the factory for details on custom cable configurations to meet your specific requirement. Using cables other than those supplied by Current Ways will compromise the IP67 rating, voiding the warranty.

10 of 43

Pin 1 has a +12V chassis referenced output capable of up to 1A (not for general purpose, this is an isolated current limited output). Pin 2 is a switched return for the thermostatically controlled fan function, described elsewhere. Pin 3 is a controlled return for an external LED for charger status indication, described elsewhere. This external LED can be powered by the Pin 1 12V source, or an external source of 12V. Pins 4 and 5 are for interlock function CONNECTIONS TO THE CHARGER; COMMUNICATIONS CONNECTOR: The connector panel houses a 9 pin male contact connector for the function of CAN communications, status relay contacts, J1772 pilot tone and proximity connections, and interlock. Current Ways cables must be used to preserve the warranty. Please consult the factory for details on custom cable configurations to meet your specific requirement. Using cables other than those supplied by Current Ways will compromise the IP67 rating, voiding the warranty.

CAN Communications Cable 056160 CAN communications signals are on Pin 1 for CAN + (high) and Pin 2 for CAN (low). These signals are electrically isolated from chassis and all other signals within the charger. The CAN interface complies with the current CAN 2.0 B, 500 kHz communications standards. Other bit rates can be programmed if desired via the available VIP Control software interface. Note that no CAN terminating resistances have been placed within the charger. The choice of terminating resistor location can be very sensitive and is installation dependent, and may require some experimentation on the part of the user. Typically a 120 ohm terminating resistor should be placed at the last physical location of CAN connections in a string of devices on the bus. An isolated 2A rated normally open relay closure is available on Pins 3 and 4. These are cold relay contacts only they do not supply power. They can be used to control an external 12V source feeding for example a master BMS or other devices. These relay contacts close upon booting up of the internal microprocessor after AC power is applied, and stay closed as long as

11 of 43

the charger is available and ready to charge. The contacts will open during a delayed charging start, as with programmed time of day charging (for example when a delay of charging is desired until cheaper time of day electric rates is available). Pins 5, 6, and 7 are related to SAE J1772 charging station controls. Pin 5 is the pilot tone input. Pin 6 is the pilot tone and proximity signal return (chassis connected). Pin 7 is the proximity signal input. A full functional description of these signals is described elsewhere in this manual, and also in the SAE publication for J1772 Standards dated January 2010. Pins 8 and 9 are for interlock function and the mating connector must have an internal jumper between the two pins. CONNECTIONS TO THE CHARGER; GROUNDING LUG: A M4-.7 threaded stud is on the connector panel that must be used to securely connect the chassis of the charger to the frame of the vehicle or service earth, depending on where the charger is installed. COOLING Air Cooled Chargers: The CA10x03 units are air cooled by means of internal fans impinging forced air upon a finned heatsink. Two fans mounted on the heatsink need a source of free air; mounting the unit in a closed space will result in overheating and poor functional performance. Allow free space of at least 6 inches on both the inlet (connector side) and outlet of the heatsink. The fans are protected against water splash or immersion, but care must be used to protect them against dirt or other solids clogging the heatsink. Operation up to 65C ambient air is possible; but best performance will be obtained by significantly lower temperatures for inlet air. The built in fans are thermostatically controlled and will activate when the chargers internal temperatures are approximately 45C. No user interaction is required, other than to make sure that fresh air is available and the inlet and outlet for the fans and heatsink are not blocked. COOLING Liquid Cooled Chargers: The CL20x03 units are liquid cooled by means of forced liquid through the cold plate. A 50/50 mix of aluminum compatible anti-freeze and water should be used; plain water will cause contaminant buildup within the cold plate. Approximately 4 liters per minute of flow is needed for best cooling and low pressure drop across the cold plate. With this flow rate, there will be approximately 3psi pressure drop across the cold plate during operation; the maximum inlet pressure must be limited to 15 PSI. Fittings are supplied to attach standard 3/8 rubber hose for inlet and outlet cooling liquid. Due to the high efficiency of the liquid cooling system, operation is possible with up to 75C ambient inlet cooling liquid temperature. Note: the maximum static inlet pressure must be limited to 15 PSI. This is to preserve the integrity of the seals in the cold plate and internally to the charger. The Pump/LED accessory cable P/N 056158 allows for use of 12V external pump (with 1A max current draw) to be powered by the charger. This external pump will be thermostatically controlled by the charger; whenever the internal temperature of the charger approaches 45C, the 12V return on the pump cable will connected to the 12V return, turning on the pump. If your particular pump requires more than 1A, the pump output from the charger can be used to activate 12 of 43

an external relay, effectively thermostatically controlling the external pump. See the Pump/LED cable drawing for connection details later in this manual. INTERNAL MODULE DESCRIPTIONS: A pair of functional modules, one for the AC input or PFC, one for the DC output or DCDC converter, is utilized within the charger. All components of mass are potted, clamped, or otherwise secured to the baseplate for rigidity, shock and vibration tolerance. All connectors must be in place for the charger to operate via an interlock system built into each connector. SINGLE UNIT OPERATION: A single 3kW charger is a complete high voltage charging system and can be vehicle or externally mounted for operation with a traction battery. All connections must be made as described. The charger is controlled by the CAN bus interface. See other sections of this manual for the messaging information needed to program a controller. Convenient manual, automatic stage charging, and BMS control options are standard in the chargers control programming, and can be setup and monitored via the available Windows based VIP Control software program from Current Ways. MANUAL OPERATION: Fully manual operation is setup and controlled via the VIP program. It is a graphically based user interface program, and allows full control and monitoring of the charger parameters. Voltage, current, power, enable/disable, charge progress and fault reporting, as well as time of day and a few other features are available on the on the GUI screen. STAGED CHARGING: This mode is setup via the available Windows based VIP Control GUI program to set up the storage batterys charging characteristics. Duration in stage, voltage, current, power, charging stage rests, time of start, time of completion, etc. can be programmed in up to 5 complete charging stages. This feature is most useful where a BMS system is not utilized, such as with flooded cell based or AGM style battery systems, as well as other battery technologies. BATTERY MANAGEMENT SYSTEM (BMS) CONTROLLED: The BMS (utilizing LHVs published CAN message protocols) is in full control of the charger voltage and current settings at all times. The BMS monitors and understands each cell state and commands the charger to output the appropriate current levels to properly charge the battery in bulk, equalization, or balancing modes. Several popular BMS technologies are supported, with and without the use of a master BMS system module. PARALLELING OF CHARGERS: The chargers are designed so that parallel operation for multiples of 3kW of output power is possible and simple to implement. Simple paralleling of the AC input connections, the DC output connections, the CAN + and CAN- connections is all that is physically required to put multiple units into parallel operation. Each unit is Voltage, Current, and Power controlled enabling this simple paralleling operation. Up to 20 chargers can be paralleled in this manner, for up to 60kW of charging power. In parallel operation, power up of the multiple units should be done simultaneously. The units will communicate with each other over the CAN bus, and one unit will assume the role of master, and the other units will become slaves. The master unit will then communicate with 13 of 43

the host, so the host essentially a single charger capable of the power levels of the paralleled units. The slave units will be in communication with the master, not the host, and will take commands directly from the master. When full power levels of the paralleled devices are demanded, all units will deliver power into the battery as classical current sources. When power levels less than the number of chargers is demanded, slaves will be shut down in sequence, to the point where only the master will deliver power if the demand is less than what one charger can deliver. This method of control has been implemented to maximize line power utilization efficiency. An example of this would be during full charge under BMS control (master and slaves delivering full power), then low power balancing (only master active and delivering low power). For AC power, each charger requires up to 16A for full power operation above 208VAC. Sizing of source, breakers and wiring must accommodate these current levels. Typical home installations will be single phase, in which case all line, neutral, and ground connections to each charger are simply paralleled (no diagram shown). Where available, 3 phase connections can be utilized. Some simplified typical 3 phase connections are shown below; note that most home (if 3 phase equipped) and commercial wiring utilizes Wye connections.

Three Chargers on Wye connection

Three Chargers on Delta connection

14 of 43

SECTION 3 - CA10X03 and CL20X03 Product Family Air Cooled Version (CA10x03 models)

Front View

Connectors

15 of 43

Front Dimensional View

Side Dimensional View

16 of 43

Mounting

Pattern View

17 of 43

Liquid Cooled Version (CL20x03 models)

Front View

Connectors

18 of 43

Front Dimensional View

Top Dimensional View

Side Dimensional View

19 of 43

Liquid Cooled Mounting View

20 of 43

AC INPUT CABLE 056155

DC OUTPUT CABLE 056156

21 of 43

PUMP/LED CABLE 056158

COMMUNICATIONS CABLE 056160

22 of 43

J1772 CTRL CAN BUS, I2C BUS 4 AC CURR SNS AC VOLT SNS PFC T SNS DCDC T SNS 6

FAN/PUMP/LED CONN 056152 ISOLATION AND J1772 uP 4 30 PFC CTRL ENABLE / FEEDBACK DCDC CTRL

uP CTRL

COMMS CONN 056161 BIAS SUPPLY 8 4

AC INPUT CONN 056150 3

400V BUS

GATE CTRL/PRI I FB

400V FILT

PRI 1

CHARGER INTERNAL BLOCK DIAGRAM

GATE DRIVE

PRI 2

23 of 43
2 PFC A CTRL PFC B CTRL AC LINE FILT/ 20A FUSES PFC BOOST STAGE

14

DC-DC CONV STAGE DC OUTPUT CONN 056149 4

SECTION 4 Specifications

WARNING: TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH. DO NOT REMOVE ANY OF THE COVERS ON THE CHARGER. DOING SO WILL EXPOSE POTENTIALLY LETHAL VOLTAGES AND VOID THE WARRANTY. THERE ARE NO FIELD SERVICEABLE PARTS INSIDE. END USER IS REQUIRED TO INSTALL FUSES ON THE DC OUTPUT CABLE, BOTH POSITIVE AND NEGATIVE, AS CLOSE TO THE BATTERIES AS POSSIBLE. REFER TO THE USER MANUAL FOR RECOMMENDED FUSE SIZES. TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! ALTHOUGH THE CONNECTOR SYSTEM UTILIZED IS CONSIDERED FINGER SAFE, THE USER MUST DISCONNECT THE BATTERY BEFORE TOUCHING OR REMOVING THE BATTERY FUSES OR REMOVING THE DC OUTPUT CABLE FROM THE CHARGER. FAILING TO HEED THIS WARNING MAY RESULT IN INJURY OR DEATH.

24 of 43

AC Input: Voltage: 100-240VAC nominal line, single phase, 50 to 60Hz Current: 16A maximum >150VAC input, 12A maximum <150VAC (unless overridden by operator via GUI screen) Power: <3600W at 3000W output Power factor: >0.99 at 3kW output; >0.97 at 1kW output Harmonics: designed to meet EN61000-3-2, FCC Part 15 Class B Efficiency: >90% at 3kW output; >85% at 1kW output Leakage current to chassis: <0.75mA at 240VAC designed to meet per UL2202 Input isolation: 2750VDC / 60 seconds to chassis designed to meet per UL2202 Holdup: >20mS above 90VAC Inrush current: <40A at 240VAC Fuses: internal non-user accessible fuses at 20A on both lines Input connector mandatory use of Current Ways 056155 AC input cable; Tyco 3 pin 280 style with 10 3 conductor orange jacketed shielded cable attached; o Pin 1 Ground/Earth/Chassis connection, wire is identified by 1 ink marking or green tape band; o Pin 2 is Line or Hot, wire is identified by black color; o Pin 3 is Line or Neutral connection, wire is identified by 2 ink marking or white tape band.

Controls Input: Communications connector mandatory use of Current Ways 056160 Communications cable with 3 7 conductor shielded jacketed cable attached; o Pin 1 is CAN HI, Pin 2 is CAN LO, o Pins 3 and 4 are 2A rated NO Relay contacts, o Pin 5 is SAE J1772 Pilot Tone Signal input, Pin 6 is Pilot tone return/chassis, Pin 7 is SAE J1772 Proximity Detection Signal input, o Pins 8 and 9 are jumpered internally for use with the interlock circuitry. Pump/LED connector mandatory use of Current Ways 056158 Pump/LED cable 3 3 #24 conductor shielded jacketed cable attached; o Pin 1 is +12V SELV (isolated low voltage) output at 1A maximum, o Pin 2 is FAN or PUMP switched return (activates upon internal temperatures rising above 40C), o Pin 3 is LED switched return (activates when LED is to be on), o Pins 4 and 5 are jumpered internally for use with the interlock circuitry. See www.CurrentWays.com for more details on available cable kits

*DC Output (with 208VAC input or above): Low Voltage Output Range I units (CA10L03, CL20L03): 112 to 225VDC for full constant power output up to 3kW 27A maximum output current at 112VDC 13.5A maximum output current at 225VDC Output current increases as output voltage decreases to maintain constant power of 3kW max Below 112VDC down to approximately 5VDC output, the maximum output current is limited to 27A

25 of 43

 Outputs must be externally fused at 30A (ATM30 or KLKD30 fuses) on both positive and negative output leads; fuses must be installed as close to the battery as possible Output connector - mandatory Current Ways 056156 orange jacketed shielded 2 individual conductors 600V rated 3mm #10AWG equivalent; positive is orange conductor marked with red tape bands, negative is black conductor marked with black tape bands, chassis is woven shield braid High Voltage Output Range II units (CA10H03, CL20H03): 225 to 450VDC with constant power output up to 3kW 13.5A maximum output current at 225VDC 6.7A maximum output current at 450VDC Output current increases as output voltage decreases to maintain constant power of 3kW max Below 225VDC down to approximately 10VDC output, the maximum output current is 13.5A Outputs must be externally fused at 15A (ATM15 or KLKD15 fuses) on both positive and negative output leads; fuses must be installed as close to the battery as possible Output connector - mandatory Current Ways 056156 orange jacketed shielded 2 individual conductors 600V rated 3mm #10AWG equivalent; positive is orange conductor marked with red tape bands, negative is black conductor marked with black tape bands, chassis is woven shield braid

Power Limits: Note that internal current limiting controls keep the AC input current below 16A when the AC input voltage is above 150VAC; this will result in the output power being automatically limited when line conditions are insufficient for full power output (typically between 150 and 207VAC input). Likewise, when operating below 150VAC, the line current is limited to 12A, and output power will be similarly automatically limited. Battery Cable Voltage Compensation: Note also that battery cable compensation for output line losses has been built into the charger. This function is transparent to the user, and adds in a small voltage compensating value to the voltage programming figure, Vpgm in the following manner: Vdemand + Iout*Rout = Vpgm Vdemand is the value of output voltage desired entered by the user on the VIP screen GUI software, or the voltage output as demanded by a BMS system. Iout is just that the output current value real time, and Rout is the preprogrammed value of the total output resistance from the sensing point within the charger to the end of the battery cable. The nominal Rout is preprogrammed at 0.08 ohms, which has been found to provide accurate results when the standard 10 cable is used. If voltage inaccuracies are found when using different lengths of battery cables, this figure can be changed in .01 ohm increments up to 1 ohm on the VIP Control Screen GUI software.

26 of 43

Output General: Input line and output regulation is <1% Output noise and ripple below 20MHz is <1% Setpoint accuracy <2% for voltage and current parameters; and <4% for power Temperature of operation: -20C to +65C ambient air temperature for air cooled units; -20C to 75C ambient coolant temperature for liquid cooled units Over voltage protection and shutdown occurs at ~110% of range maximum Over current protection and shutdown occurs at ~110% of range maximum Over power protection and shutdown occurs at ~110% of maximum 3kW Output is short circuit protected by active electronic means and required external mechanical fuses Output is reverse polarity protected by passive electronic means and required external mechanical fuses Output isolation: 1000VDC to chassis

Protection Features: The following are all protection modes that will result in a fault signal (red LED indication) and unit shutdown: Over voltage protection at ~110% of range maximum Over current protection at ~110% of range maximum Over power protection at ~115% of maximum 3Kw Output is short circuit protected by active electronic means and required external mechanical fuses Output is reverse polarity protected by passive electronic means and required external mechanical fuses (note that severe internal damage to the charger may occur if the required external fuses are not used or properly installed) Thermal shutdown commences at approximately 55C ambient air temperature or 65C ambient cooling liquid temperature; power levels will be automatically decreased above these points, and full thermal fault shutdown will occur at approximately 10C higher temperatures. Internal housekeeping bias supply out of range AC input voltage out of range (below ~80VAC and above ~260VAC) Note: the AC voltage sensor requires that the charger be active and producing above approximately 400 watts for this reading to be accurate. Low and inaccurate AC Voltage readings are expected when the charger is producing low power or is disabled. LED Indicator Functions: The green LED indicator will give information as to the status of the charger as follows: Normal indications: o Solid normal operation for single or master unit o Slow Blink normal operation for a slave unit o Two Slow Blinks normal stage charging o Three Slow Blinks standby for time of day charging Fault indications: o One Fast Blink Over Voltage Error 27 of 43

o o o o o o o

Two Fast Blinks Over Current Error Three Fast Blinks Over Power Error Four Fast Blinks High Temperature Power Reduction Five Fast Blinks Over Temperature Error Six Fast Blinks AC Input Voltage Out of Range Seven Fast Blinks Internal Bias Supply Out of Range Eight Fast Blinks Connector Interlock Open

Environmental: Both air and liquid cooled models are rated for immersion up to 1 meter for 30 sections when Current Ways sourced cables are attached. Fans on the air cooled model will survive immersion; their function will return when dry. The air cooled models will operate from -20C to +65C ambient air temp, max 95% RH condensing or non-condensing ambient air. Power will be reduced when temperatures exceed approximately 55C, and the unit will shut down when temperatures exceed 65C The liquid cooled models will operate from -20 to +75C ambient coolant liquid at the inlet with minimum of 4 liters per minute of coolant flow. Pressure drop will not exceed 4 PSI. Do not exceed 15 PSI static pressure at the inlet. With 65C inlet coolant temperature, the unit will begin to derate power until 75C inlet coolant liquid is reached, at which point the unit will shut down. Note: Coolant liquid composition is a recommended 50/50 mix of aluminum compatible antifreeze mixture held to <65C. Section 5: Computer Interface Control of the Charger is executed via the external CAN bus connection (Pins 1 and 2 on the 9 pin Communications connector). A USB to CAN converter must be used between the unit and the controlling PC, running Microsoft Windows XP or later operating system. A CAN Bus connection must be made between a USB port on the computer and the unit. The CANUSB product from LAWICEL www.lawicel.com or www.canusb.com has been tested with the Charger. Another adapter is from Peak Systems; the PCAN CAN-USB adapter has been tested, and must be used for internal firmware updating the Charger. The Peak PCAN adapter and software is available at: http://www.phytec.com/products/can/pc-can-interfaces/peakusb.html A cable between the 9 pin DSUB connector on the adapter and the 9 pin circular connector on the charger must be made. Connect only the CAN HI and CAN LO signals from the Current Ways 056160 communications cable assembly are connected to the DB9 female connector that plugs into the adapter. The black wire from Pin 1 of the 9 pin circular cable goes to pin 7 on the DB9 female connector for the adapter, and the white wire from the cable goes to pin 2 on the DB9. No other connections are needed (do not connect the +5V or GND). Wire connection side of DB9 female connector shown:

28 of 43

Current Ways 056160 Communications Cable shown:

If this is the last or only other device on the CAN bus, install a 120 ohm 1/8W resistor from pin 2 to pin 7 on the DB9 female connector. This will properly terminate the CAN bus with the correct impedance for best communications signal integrity, as there is no terminating resistor within the Charger. You now have the proper physical interface for the CAN USB adapter to the Charger and can proceed to the software driver and Current Ways VIP Control Software GUI installation below. Section 6: Software Installation This first section is for installing the Lawicel CANUSB adapter; if you have the Peak PCAN adapter, first go to the Installing the Peak PCAN CAN-USB Adapter later in this section. This installation is based on a host computer running Windows XP professional with Plug and Play enabled. Slight modifications might be required if the host computer is running either Vista or Windows 7. It has been verified that the Lawicel CANUSB adapter runs with any of these operating systems. Installing the Lawicel CANUSB Adapter Step 1 - Insert the Current Ways CD supplied with the Battery Charger. Open up the CD drive window and view the files. Step 2 - Plug the Lawicel CANUSB adapter into a free USB port on the host computer. Note that this exact hardware port must be used; other USB ports will not function with the installation (only for XP; later Windows OS do not have this restriction). Step 3 - Plug and Play will notify new hardware found.

29 of 43

Figure 1 Select No not this time and click Next since the install files are located on the CD; Windows update is not selected.

Figure 2 Select Install from a specific location; the CD root directory. 30 of 43

Figure 3 Select your CD drive for the installation source and click Next.

Figure 4

31 of 43

Lawicel CANUSB has not passed Windows Logo Testing; continue anyway.

Figure 5 Click on finish when the first installation has completed. Step 4 - Now navigate to Device Manager. The easiest way to do this is to right click your mouse over the My Computer Icon on your desktop, and then select Properties then select Device Manager. Or you can navigate to the Windows Control Panel and find it buried in the Administrative Tools/Computer Management/Device Manager. Ensure the view selected is By Type. You can select this by right clicking the mouse while hovering the cursor over Device Manager. Open Up or double click over the Com Port and the Universal Serial Bus Controller to see what devices are installed. At this point the Lawicel Com port will not show up, because only the Controller has been installed.

32 of 43

Figure 6 Double click the Lawicel CANUSB line under Universal Serial Bus Controller. Click on the Advanced tab and check the VCP box. Click the OK button and minimize the screen. Step 5 - Unplug the CANUSB Adapter from the host computer and wait about 2-3 seconds, then plug it back in. You should again get a Found New Hardware indication. Follow the same instructions outlined in section 3 above for installing new hardware.

33 of 43

Figure 7 Maximize the Device Manager window and note the second hardware installation; there should be a Lawicel Com Port installed under Com Ports in addition to the Controller com port assigned to the adapter in the Device Manager. Note the Com Port assigned to the new adapter just installed, it is Com Port 11 in this example. You have successfully installed the Lawicel CANUSB adapter to your computer. Installing the Peak PCAN CAN-USB Adapter This information for this section will be from the PCAN USB User Manual from PEAK Systems. http://www.phytec.com/products/can/pc-can-interfaces/peakusb.html

The Peak PCAN CANUSB adapter is another supported communications interface for the Current Ways Chargers. If you desire to use this adapter, please download the installation information and drivers from their website above.

The PCAN CANUSB adapter must be used if updating the internal firmware of the charger; the Lawicel device will not function properly for this activity. Please contact the factoryfor more details. Second: Installing the Current Ways VIP Control Software GUI setup and connect Step 1 - Navigate to the CD supplied from Current Ways. Open the Current Ways GUI Version 1_4_4_11 folder (or latest version). Copy the ChargerDiag.exe file to the desktop or 34 of 43

other suitable working folder on the host computer. The executable file will try and write a .ini file to the same location the exe file is saved at, so operation from the CD will not work. Double click on the saved file ChargerDiag.exe.

Figure 8 Note the Absence of Grid lines on the graphical display. The CAN adapter has not yet been connected. Step 2 Attach all connectors. Connect the Charger to the CANUSB Adapter DB9 connector to the Communications 9 pin circular connector (see above for connection diagram). Ensure the AC Input and DC output connectors are plugged in and locked. There will be an audible click when these connectors are locked. Ensure the 5 pin circular connector/harness exiting is plugged in securely either to the fans on the air cooled unit or to a pump or pump controlling relay if this function for circulating cooling liquid is desired. Step 3-Apply AC power to the Charger. You should hear the fans spin up slightly then turn off, or the pump start and then shut off. The air cooled units have a green LED visible by the fans, it should be lit see elsewhere in this manual for LED function definitions. Open the Connection Settings menu from the top left of the screen.

35 of 43

Figure 9 Select Can over Serial Com Port top left of screen, then enter 500Kbit/sec for the Baud rate, and enter the suitable com port number assigned to the adapter - in this example it is Com Port 11. Please disregard the connection hardware and baud rate boxes in the lower section of the screen; these are used in the event a different adapter is used. Now click on Connect top middle of screen

36 of 43

Figure 10 When the GUI connects to the CANUSB Adapter the Grid lines and data lines will appear in the graphical display. The GUI Version number will display at the top of the screen. The current version is 1.4.4.11. see www.CurrentWays.com for the most up to date version. Now click on the connect to charger button and the Charger serial number and code version will appear at the top of the screen

37 of 43

Figure 11 You have successfully connected the Charger to the host computer via the CANUSB adapter and are ready to operate the unit.

38 of 43

Section 6: Current Ways VIP Software GUI Operation with Charger

Figure 12 Note the real time clock is displayed under the graphical display. The clock will sync up to the host computers real time clock when you click on get time. The Real time clock has been tested at up to 10 days with no loss of time. Further testing is still under way. The Slider controls will vary the Voltage, Current and Power demands for the charger. The sliders do not have very fine resolution, so in the event more accuracy is desired; enter the setting into the numerical blocks to the right of each slider, i.e. 9.25A or 850W. Anytime the demands are changed, the command will not be sent to the charger until the update button at the lower left of screen is clicked. It is advised to check the fault reset box such that any time the DUT is enabled it starts with a clean session. The right hand side of the screen only shows readings, alerts and settings. There are no user selectable buttons or commands here. The PFC and DC-DC modules are monitored for Temp. The temp of each module is shown on the GUI. In the event the power must be reduced due to an over temperature condition, the greater of the 2 readings will trip the event. The High or Low voltage Mode box will be checked depending on whether the charger is configured internally for either Range 1 (Low) or Range 2 (High) Voltage Mode. The next lower 7 grayed out boxes are alerts indicating what the failure that occurred is. It could be an over temp condition with either the PFC or DC-DC module, An Output OCP event (Over Current Protection), Output OVP (Over Voltage Condition), Output OPP (Over Power Condition), Output connector interlock (Interlock has been opened), bias voltage out of range 39 of 43

(Internal Bias is out) or AC out of range (indicating either a very low line or very high line condition. The mode the charger is operating in will be checked, Constant Voltage, Constant Current or Constant Power. The settings and output loading will determine which mode the charger operates in. If you want to change modes, you must change the load impedance or settings. If you want constant voltage mode you can make the current and power maximum and start with a lower voltage setting, then walk it up. At some point it may switch to constant current then constant power depending on the load impedance. All 3 modes have separate independent control loops and are regulated. The Fuse Voltage Drop should be ignored. A fuse must be inserted between the Charger and the Battery at the battery. This is left to the user to accomplish. We used to have fuses in our product, but have determined that since we have current limit and fail safes designed into our product, the fuse really should be provided in the final system at the battery. In the event a failure occurs during operation, for whatever reason, you can check the fault reset box and try to enable the DUT again. If a line outage or brownout condition has occurred, the AC out of range will be checked and the charger will try to re enable within 30 minutes. Section 7: Stage Charging Setup

Warning: This is a potentially dangerous method of charging, to both property and person, and we strongly recommend using a Battery Management System (BMS) when charging any battery, whether Lithium, Lead, Nickel or??? based. Before entering into the process of stage charging, you must do a sanity check on the battery pack every time to make sure that none of the cells are bad or shorted. If you have a shorted cell it is possible to overcharge the other cells in the pack and cause the rest of the cells to fail. Current Ways is not responsible for any damage as a result of improper charging. Stage charging programming is available for battery systems without BMS. The Charger supports five stages (0-4) of charging. Each stage consists of a stage change trigger, a stage change trigger value, voltage, current, power, and time in stage limit (for the case where a programmed condition is not met, or if a sleep stage is desired to rest the battery between stages). The triggers for changing to the next stage are: voltage above set point, voltage below set point, current above set point, current below set point, power above set point, power below set point,

40 of 43

and sleep where the charger will not be charging the batteries and provides a cool off period for the battery and will advance to the next stage on time out criteria only. Note: when using one of these criteria, it is very important that the voltage current, or power settings are appropriate (i.e., when you are switching on a voltage limit of 150V, you should set the voltage limit to 153 or higher; in other words, you should shoot for a 2% over or under mark for the actual trigger. The granularity of the cell voltages come into play here especially at low numbers of cells in a battery). To program stage charging, there is a menu item on the VIP Software GUI program, on the main page. Select this, and enter values into the screens for each stage, and click update to set the stages. Once the parameters are set, the charger will enter into stage charging automatically when power is next applied, unless the charger has been previously configured for BMS charging. If the charger has been previously for BMS operation, contact the factory for assistance. Section 8: Battery Management System Interface It is highly recommended that a Battery Management System be used for the proper maintenance and charging of any multi-cell power traction or storage battery. Thus, the Current Ways Charger is compatible with several Battery Management Systems via the CAN bus communications protocol. The Current Ways charger has its own BMS command language to allow for automatic BMS control operation, and additionally it is compatible with the following standards: For BMS control, the charger responds to two published standard messages with CAN IDs of 610H and 618H. The charger will work out of the box with these standard message formats. These parameters can be reconfigured if need be; contact the factory for details. Another BMS that is supported is supplied by Flux Power. Use of this BMS requires configuration of the charger prior to operation; the configuration is done through a Flux tab on the VIP Control Software GUI for chargers configured to work with the Flux BMS. To see how to turn on Flux BMS compatibility, contact the factory for details. Flux programming involves configuring the cutback voltage of the battery pack, the full voltage of the battery pack, the shutoff voltage of the battery pack, the number of physical BMS boards, and whether or not the charger cuts back power when the BMS enters balancing operation. Section 9: Updating the Internal Charger Control Firmware Current Ways technical staff is always seeking ways to improve the charger, and to that end, it may be necessary to update the internal firmware in the charger. Please contact the factory for details. Section 10: Integrated SAE J1772 Control of the Charger The BC-Series chargers have the integrated SAE J1772 interface and meet all SAE requirements for operation by an EVSE. This allows the onboard BC-Series EV Charger to communicate with the EVSE to charge the vehicle. The proximity detector will shut down the charger within 100ms if the release button on the charge nozzle is pressed. 41 of 43

Appendix A - Mechanical Outline Drawings: Air Cooled Models:

42 of 43

Liquid Cooled Models:

43 of 43