Siemens VersiCharge Ultra 175 User manual

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Maintenance Manual
VersiCharge Ultra ™
 kW DC fast charger

Table of Contents
Important safety instructions 
Block diagram 
Maintenance intervals 
User unit maintenance 
User unit maintenance checks 
Isolated power unit maintenance 
Isolated power unit maintenance checks 
Electrical safety checks 


This manual contains information about maintenance for the
VersiCharge Ultra  kW charger model: kW DC.
The purpose of this document is to guide the Siemens certified
service agent through a series of preventative maintenance
checks for the VersiCharge Ultra kW DC charger system.
This guide is a living document and is updated as changes occur.
It is the intention of Siemens to update this guide periodically as
new procedures and technologies are developed and employed.
The document is subject to updates without notification.
The scope of this document covers the maintenance interval
schedule to be carried across all the sub-systems of the
VersiCharge Ultra kW DC charger system. The sub-systems
include:
•User Unit: The user unit provides an interface for the user (the
electric vehicle driver/owner) and uses the CHAdeMO or
Combo  (CCS) connector to connect one electric vehicle to
the power supply.
•Isolated power unit: The IPU outputs regulated  -  V DC
to the user unit. It also provides galvanic isolation of the
charging system from the AC grid interface through the
isolation transformer, as well as charge control and
communication to back-office services.
CRITICAL
Except as expressly stated herein, all maintenance must be
performed by a Siemens certified service agent only. In the
absence of a certified service agent, the actions recommended
in this manual should not be actioned.
All maintenance work should be conducted ONLY when the site
is completely de-energized.
For assistance with maintenance of the charger, contact your
supplier, or Siemens Customer Support.
Identifying symbols
CAUTION
RISK OF ELECTRIC SHOCK
CRITICAL
Operating temperature:
-° to °C / - to °F
Weather rating:
User unit
IP Electronics Enclosure
NEMA Type A
IPU
IP
NEMA Type R
CAUTION
In the event of a circuit breaker trip, the charger must be
inspected by a Siemens-certified service agent before the
charger is re-energized.
Important safety instructions
Save these instructions
Description Catalog No.
These VersiCharge Ultra ™ kW DC Charger Operating
Instructions are for:
Dispenser Unit US:VSCULTDUSAG
Transformer US:VSCULTPUSAG
Maintenance Manual | VersiCharge Ultra ™


Block diagram
Simplified
Detailed (excluding LV board)
Customer LV
Distribution
Board
Isolated
Power Unit User Unit
VersiCharge Ultra ™ | Maintenance Manual


Key
C = Check, R = Replace
User unit
Part Test Action 12 mth 2 yr 5 yr
Liquid cooling system Coolant level inspection If too low, top off C
Charge plug/cable Inspect cable and plug Inspect cable and plug C
Coolant pump (front) Check for operation Periodic replacement C R
Radiator fans (x2) Inspect and clean Clean/replace as
required (1)
C R
Isolated power unit
Part Test Action 12 mth 2 yr 10 yr
Front door filters Check filter Clean/replace as
required (1)
C R
Primary Transformer Inspect electrical
connections for signs of
heat or corrosion
Ensure connections are
tight and firm
C
Rear door fans + filter (x2) •Check filter
•Check for airflow
Clean/replace as
required (1)
C R
UPS battery Check battery controller for
alerts/alarms
Check and replace batteries
as required
C R
Notes:
1. Filter cleaning/replacement is environment dependent. Perform more frequently in higher pollution environments.
2. Used batteries must be disposed of in accordance with applicable national and local environmental regulations.
They can also be returned to the manufacturer.
All units
Part Test Action 12 mth 2 yr 5 yr
Tilt sensor/door switches Verify correct operation If it does not operate
correctly, troubleshoot
C
Electrical safety checks See section
Electrical Safety Checks
C
Maintenance intervals
Maintenance Manual | VersiCharge Ultra ™


User unit maintenance
The following image shows the features and components of the VersiCharge Ultra 175kW DC charger.
Maintenance performed by the user is expressly limited to
General Exterior Maintenance and Snowfall Areas, as defined
in this document. All other service must be conducted by
qualified personnel.
If there is any damage to the charger, contact your supplier.
It is recommended to perform general maintenance at least
every six months, depending on the environment. In harsh
environments, general maintenance should be performed
more often.
General exterior maintenance
Regular cleaning is recommended to avoid accumulation of
debris/dust/dirt on or around the unit. Wipe surfaces with a
soft cloth dampened with water, or use an (alcohol-based)
cleaner for harder to remove marks.
Do not spray with high pressure cleaning hoses or use
abrasive chemicals.
Snowfall areas
Regularly remove snow build up if present in front of the
radiator panels.
This should be checked daily in areas with high snowfall.
Cable management
Downlights
Status indicator
aReady to charge
aCharging ongoing
aOut of service
.” screen
Control buttons
Plug holder
Charge plug – CCS
RFID or optional credit card reader
Charge plug – CHAdeMO
(only for dual charge cable variant)
VersiCharge Ultra ™ | Maintenance Manual


User unit maintenance checks
General external checks
. Surfaces
Check for cuts, damage, and debris.
If debris is present, remove it.
If you find damage, contact your supplier.
. Metalwork
Check for damage and corrosion.
If present, contact your supplier.
. Interface panel
. Check the HMI for damage/signs of faded color/pixels that
are clearly visible.
. Press each button and check if they work.
. Plug holders
Ensure there is no debris or damage inside or around the plug
holders and plug holder hinges.
If present, remove debris/notify the supplier.
. Cable Management system
Pull on the cables to check the retraction system of the cables.
If blocked, contact your supplier.
Coolant level and radiator fans check
. Coolant level inspection
. Check if the coolant is at the correct level.
Note: The coolant should be above the level indicated by
the arrows in the following image.
. If the coolant level is below the half-way arrow mark of the
hose, inform the supplier.
. Radiator fans
. Periodically check for debris/damage.
. Clean fins to ensure free airflow.
CAUTION
Clean with water and soft-bristled brushes and/or low-
pressure hoses only to avoid bending or damaging the fins.
Allow to air-dry before operating.
Cable management
Downlights
Status indicator
aReady to charge
aCharging ongoing
aOut of service
.” screen
Control buttons
Plug holder
Charge plug – CCS
RFID or optional credit card reader
Charge plug – CHAdeMO
(only for dual charge cable variant)
Maintenance Manual | VersiCharge Ultra ™


User unit maintenance checks
Charge cable checks
. Inspect both cables and plugs.
. Check for cuts, holes, cracks, sharp edges, and exposed
copper.
. If you observe any cuts, holes, cracks etc, contact your
supplier.
.Check the contact pins for signs of corrosion.
. If corrosion is present, contact your supplier.
VersiCharge Ultra ™ | Maintenance Manual


Isolated power unit maintenance
The following image shows the features and components of the VersiCharge Ultra 175 DC Charger IPU.
. IPU Main Disconnect Switch
. UPS Batteries
. Escutcheon Panel
. IPU Rear Fans + Filters
. Door Switch (top)
. Door Switch (bottom)
. Isolation Transformer
. Control Shelf
. Rectifier Racks
. Data Module
. IPU Front Filters
The following maintenance can be performed by the owner/
user. All other service must be conducted by qualified service
personnel.
If there is any damage to the unit, contact your supplier.
It is recommended to perform general maintenance at least
once a year, depending on the environment.
In harsh environments, general maintenance should be
performed more often.
General exterior maintenance
Regular cleaning is recommended to avoid accumulation of
debris/dust/dirt on or around the unit. Wipe surfaces with a
soft cloth dampened with water, or use alcohol-based cleaner
for harder to remove marks.
Do not spray with high-pressure cleaning hoses or use
abrasive chemicals.
Snowfall areas
Regularly remove snow build up if present around the inlet
fans.
This should be checked daily in areas with high snowfall.
Maintenance Manual | VersiCharge Ultra ™


Isolated power unit maintenance checks
Door fans and filters
. Inspect the four filters located on the IPU front door for
accumulated dust.
. Clean or replace as required.
UPS battery
. Check the UPS controller for errors or warning lights.
. The Li-Ion UPS batteries should last - years, however, it
may be necessary to replace the batteries periodically as
part of continuous maintenance.
Doors
. Check hinges for ease of movement and spray with a
suitable water-free lubricant.
. Check the lock for ease of movement and spray with a
suitable water free lubricant.
Seals
. Check the seals for damage around the contact areas.
. If any damage, replace the seal.
Metalwork/enclosure
. Check for signs of corrosion or damage such as scratches.
. For minor corrosion or damage, use polishing or a light
sand and paint to repair.
. For major damage, contact your supplier.
VersiCharge Ultra ™ | Maintenance Manual


Electrical safety checks
It is recommended to complete the following checklist annually.
. Check the protective earth connections (around enclosure) for:
•breakage or loss
• signs of corrosion
. Measure the resistance of the main, protective earth connection.
. Inspect connections to buried earth electrode for signs of:
• corrosion
• breakage
• loss
. Inspect all buried site cables interconnecting the equipment for signs of insulation degradation.
. Check any insulating supporters and insulators for condition and fit.
. Check all connections and visible components for signs of overheating (especially IPU contactors and main power
connections).
. Check cable support/strain relief structures.
. Retorque any screw terminals (especially contactor).
. Inspect the retention of rectifier module screw terminals (these cannot be retorqued).
. Check the resistance of  Ohm discharge resistor and  Ohm discharge resistor (can be done with a DMM with the
power off).
. Retorque and check IMD connections and terminals.
. Check AC contactors in the IPU are in the released/open position when de-energized (this can be visually checked with the
power off).
. Visual inspection of SPD devices and associated fuses in the IPU.
. Evaluate the amount of deposited pollution visible in the enclosure. Consider cleaning as necessary.
. Manually engage all ten Power Unit contactors and listen for chatter or intermittent operation.
. Check isolation transformer primary / secondary connections for corrosion or heating.
Maintenance Manual | VersiCharge Ultra ™


Published by Siemens Industry, Inc. 
Siemens Industry, Inc.
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Phone: + () -
[email protected]
usa.siemens.com/versichargeultra
Article No. SIDS-T--AUS
Engineering Doc No. PREC
Printed in USA
All Rights Reserved
© , Siemens Industry, Inc.
The technical data presented in this document is based on an actual case or on
as-designed parameters and, therefore, should not be relied upon for any specific
application and does not constitute a performance guarantee for any projects.
Actual results are dependent on variable conditions. Accordingly, Siemens does
not make representations, warranties, or assurances as to the accuracy, currency
or completeness of the content contained herein. If requested, we will provide
specific technical data or specifications with respect to any customer’s particular
applications. Our company is constantly involved in engineering and
development. For that reason, we reserve the right to modify, at any time, the
technology and product specifications contained herein.