Siemens VersiCharge Ultra 175 User manual

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Installation Manual
VersiCharge Ultra 175™
175 kW DC fast charger

Table of Contents
Important safety instructions. Save these instructions 3
FCC Notice 5
Packaging, handling and receipt 6
Site configuration 7
Baseplate dimensions 9
Installation requirements and equipment 10
Unpacking 11
Installation 12
Wire and commissioning 14
Ethernet port access 16
Fiber optic access 17
Closing checklist 18
VersiCharge Ultra 175 System Installation Checklist 20
VersiCharge Ultra 175™ | Installation Manual
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Identifying symbols
CRITICAL
CAUTION
RISK OF ELECTRIC SHOCK
Equipment Grounding Conductor Symbol
øPhase Symbol
∿Alternating Current Supply Symbol
Wiring
Power and Protective Earth (PE) Conductor ratings: DC Copper
95mm2 (cross section), V90 class, rated to operate at 90°C.
Siemens recommends the use of copper cables. Refer to the
Veefil-RT 175-S Piping and Cabling document (document TRI125.
INS.016) for reference specifications.
Observe local regulations regarding wiring different circuits in
the same conduit, including the Ethernet link, if used. In
general, all conductors occupying the same conduit shall have
an insulation rating equal to at least the maximum circuit
voltage applied to any conductor within the conduit.
Important safety instructions.
Save these instructions.
This manual contains important instructions for the VersiCharge
Ultra 175 kWDC charger.
Read the installation and operating instructions before
installing and commissioning the equipment.
These instructions must be followed during installation,
operation, and maintenance of the unit.
CAUTION
The VersiCharge Ultra 175 kW DC charger unit must be
installed and serviced only by qualified electrical personnel.
To achieve EMC compliance, the chassis of the VersiCharge
Ultra 175 fast charger unit must be bonded to Earth locally
at the charger.
Grounding instructions
This unit must be connected to a grounded, metal, permanent
wiring system. An equipment-grounding conductor must be run
with circuit conductors and connected to equipment-grounding
terminal or lead on the electric vehicle charger.
Connections to the battery charger shall comply with all local
codes and ordinances.
Observe all pertinent national, regional, and local safety laws
and regulations when installing and commissioning the
VersiCharge Ultra 175 fast charger.
CRITICAL
Installation shall not be done in a: (i) commercial garage
(repair facility) or (ii) within 20 feet (6096 mm) of any
dispensing device or storage container for motor fuel or any
other potentially flammable substance.
Installation Manual | VersiCharge Ultra 175™
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Important safety instructions.
Save these instructions.
Input:
950Vdc
190A
1ø, 240 Vac
50/60 Hz
3A
The VersiCharge Ultra 175 unit must be connected to a circuit
provided with appropriate over-current protection in accor-
dance with the National Electrical Code, ANSI/NFPA 70.
Tightening torque:
Wiring terminals:
30 Nm / 22 lb-ft
Service hatch:
2 Nm / 17.7 lb-in
Weather rating:
IP65 Electronics Enclosure
NEMA Type 3R
Usage limitations
No cable extensions of any kind shall be used to extend the
VersiCharge Ultra 175 cable to connect to a vehicle.
Adaptors shall not be used to connect a vehicle connector to
a vehicle inlet.
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FCC Notice
Information to the user
(FCC Part 15.105)
Class A product:
NOTE:
This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to part 15 of the FCC
rules. These limits are designed to provide reasonable protection
against harmful interference, when the equipment is operated
in a commercial environment. This equipment generates, uses
and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful
interference which the user will be required to correct at his own
expense.
Modification warning
(FCC Part 15.21)
Warning: Any changes or modifications not expressively
approved by (Siemens) could void the user’s authority to
operate this equipment
Installation Manual | VersiCharge Ultra 175™
5

Packaging, handling and receipt
Prior to unpacking and installation read these instructions
carefully to become familiar with the VersiCharge Ultra 175 unit
packaging and handling procedures.
In all cases, the VersiCharge Ultra 175 unit must be transported
to the installation site in its original packaging, and only
unpacked at the installation site.
Installation, commissioning, and servicing of the VersiCharge
Ultra 175 unit should only be carried out by qualified personnel.
Materials:
The VersiCharge Ultra 175 unit is transported in a reinforced
cardboard crate.
Please respect the environment and recycle/reuse the materials.
.
Storage:
Store in the original packaging in a horizontal position.
Store in a dry location, protected from the weather (warehouse
conditions).
Storage temperature:
-20 to 45°C / -4 to 113°F
Handling:
Only lift the VersiCharge Ultra 175 unit packaging in its
horizontal orientation using a forklift, pallet jack or with lifting
straps and engine hoist, forklift or crane. Check the weight on
the delivery documents and ensure the lifting apparatus used is
compatible.
Receipt:
Check that the crate packaging is in good condition and that the
VersiCharge Ultra 175 unit is not damaged.
If there are any problems noted, make a formal complaint to the
carrier and notify your supplier.
Packed crate weight:
300kg / 660lbs (approx)
Crate size:
1150 (W) x 2150 (L) x 850 (H) mm
45.3 (W) x 84.6 (L) x 33.5 (H) inches
VersiCharge Ultra 175™ | Installation Manual
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Site configuration
Site survey:
A qualified engineer must survey the installation site to
determine the correct ground preparation for the size and
weight of the VersiCharge Ultra 175 unit, in accordance with
local regulations.
The VersiCharge Ultra 175 unit is best installed following the
recommended site configuration requirements.
Ground fixing:
The VersiCharge Ultra 175 unit is fixed to the ground through the
baseplate fixing holes with 4 x M16 fasteners or 5/8 inch
fasteners.
Fasteners are not supplied, as the type required depends on
the foundation used, and must be chosen by the installer
accordingly.
The fasteners should fix the VersiCharge Ultra 175 unit securely
to the foundation through the baseplate, in accordance with the
dimensions and fixing points shown in Figure 3: Base plate
dimensions.
Note: Keep the plastic inserts from the bolts for use in the
baseplate holes.
Conduit requirement:
Ø 110mm OD conduit.
When preparing the foundation, ensure that conduit and wiring
terminates above ground according to the document TRI125.
INS.016 Veefil-RT 175-S Piping and Cabling.
Foundation requirements
The foundation must be flat, even, and have the appropriate
density for the weight of the VersiCharge Ultra 175 unit.
Check the flatness and level of the foundation and level of the
VersiCharge Ultra 175 unit baseplate prior to fixing.
Communications:
A site can utilize Ethernet or optical fiber between the IPU and
UU. If the UU and IPU are configured for use of optical fiber,
then use optical fiber. If not, use Ethernet (default).
4G network capability.
Cat 6a STP Ethernet cable required with a minimum length from
the foundation surface.
Fiber Optic Cable: OM3 Multi Mode 2 Core
For detailed wiring instructions, see reference.
Installation Manual | VersiCharge Ultra 175™
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Site configuration
Servicing distance
An additional space of 700mm from the center front and rear of
the VerisCharge Ultra 175 unit is required to open the front
panel for servicing, as shown in Figure 1.
Cable range
Figure 1: Servicing distance
Do not scale
700mm
4300
Figure 2: Cable range
VersiCharge Ultra 175™ | Installation Manual
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Baseplate dimensions
Note: Do not scale. All dimensions shown in mm. A mounting stencil may be supplied by Siemens at the customer’s request.
Installation Manual | VersiCharge Ultra 175™
9

Installation requirements and equipment
These instructions provide a systematic guide for installing and
commissioning the VersiCharge Ultra 175 unit.
The VersiCharge Ultra 175 unit must be installed and serviced by
qualified electrical personnel.
Observe all pertinent national, regional, and local safety
regulations when you install and commission the VersiCharge
Ultra 175 unit.
The VersiCharge Ultra 175 unit has an IP65 electronics enclosure
rating, however, as it must be opened for installation, this is
best done in dry weather, or under cover, to avoid moisture or
debris ingress.
The VersiCharge Ultra 175 unit must be properly installed,
assembled, and commissioned according to these instructions
before it is used.
In-box equipment:
• 5mm pin hex tool to remove the M8 security screws fixing
the plastic panels.
• 4mm Allen wrench to remove fasteners on the enclosure
access cover.
• 4x M32 cable glands.
• 1x M25 cable gland.
• M10 fasteners for wiring.
• External Ethernet connector.
Required equipment (not supplied):
•Lifting apparatus. See page 3 for weights. Ensure lifting
apparatus is sufficiently rated.
•110mm OD Conduit
•4x M10 lugs and crimping equipment for wiring installation.
• 4x site specific fasteners
• Fasteners are not supplied, as the type required depends on
the foundation used and must be chosen by the installer
accordingly.
• Socket set and ratchet
• Torque wrench with 30Nm setting
• Torque wrench with 2Nm setting
• 1 x M8 lug for ground wire
Document Key:
Items shown in blue are parts that require action for that
step.
VersiCharge Ultra 175™ | Installation Manual
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Unpacking
CAUTION
Do not work under suspended loads. Two people may be
required as the unit may swing.
1. Open crate
Move the crate as close to the prepared installation site as
possible. Ensure there is enough room to maneuver the lifting
apparatus.
Remove/slide out all crate tubes to disassemble the cardboard
crate.
2. Lift VersiCharge Ultra 175 unit to upright
Securely attach the lifting straps at the top of the VersiCharge
Ultra 175 to the lifting apparatus, and gently raise to a upright
position on the shipping baseplate.
NOTE: The VersiCharge Ultra 175 unit is 2060mm tall on the
shipping baseplate.
Once upright, remove all wrapping. Ensure the connection to
the lifting apparatus is secure at all times.
Installation Manual | VersiCharge Ultra 175™
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Shipping
Baseplate
Lifting Straps

Installation
1. Remove lower front panel
Use the 5mm pin hex tool to unscrew the 4 security screws (2
per side) from the front panel, then remove them. Pull the front
panel forward to remove and safely store all parts.
2. Remove rear-lower panel
Follow this step to increase visibility and access to the mounting
holes. If visibility and access is sufficient, go to step 3. Use the
4mm Allen wrench to unscrew the 4 screws that attach the rear
panel to the enclosure and slide out to remove.
3. Remove shipping bolts
Unscrew the 4 bolts from the shipping base (optional fiber
optic interface module not shown).
4. Secure to foundation
Lift the VersiCharge Ultra 175 unit and place over the prepared
foundation. Feed the conduit and wiring through the power
in-hole, and secure to the foundation fixing points. (Fasteners
not supplied)
Note: Use the plastic inserts in the holes of the baseplate.
VersiCharge Ultra 175™ | Installation Manual
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Installation
5. Remove enclosure access cover
Remove the enclosure access cover screws with the 4mm Allen
wrench to prepare the VersiCharge Ultra 175 for wiring
installation.
The enclosure access cover has an attached gasket. Ensure this
is carefully stored to avoid damage or accumulation of debris.
6. Remove tape and attach cable glands
Remove the tape from the field wiring input holes, and fit the
supplied 4x M32 cable glands and 1x M25 cable gland.
7. Prepare wiring
Fit the individual power cabling into each M32 cable gland,
ensuring there is enough length to add the M10 lugs (not
supplied) and attach to the busbars. Fit each wire with an M10
lug.
8. Remove M10 fasteners
Each installation busbar is fitted with M10 fasteners. Remove
these ready for wiring.
CAUTION
To continue to achieve the NEMA 3R rating the power
cabling must be fitted correctly into the cable gland.
Ensure the cable is sitting correctly in the gland and tighten
to ensure no water or debris can enter. If in doubt, use an
appropriate outdoor rated sealant.
When the cable gland has been tightened, pull on the cable
to ensure it doesn’t slip.
Installation Manual | VersiCharge Ultra 175™
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Wire and commissioning
CAUTION
Wiring and commissioning of the charger is to be done by
qualified electrical personnel only.
The wiring diagram is also available on the inside of the
Service Hatch.
1. DC conductors
Attach the M10 lugs onto the negative and positive busbar
positions, as shown.
Ensure that the lugs and connection points are clean and free
of dirt before you make the connections.
CRITICAL
Clean the surface area of the mating surfaces with an
abrasive pad, and use joint compound between the mating
surfaces.
You must use a torque wrench to tighten to the specified
tightening torque, and you must apply a torque mark to the
stud and nut.
CRITICAL
Tightening Torque:
30 Nm / 22 lb-ft
Note: Refer to Siemens VersiCharge Ultra 175 Site Installation
Manual for a table of all torques used during installation.
Fix grounding yellow/green wire to the M8 grounding stud (M8
lug not supplied) on the inside channel.
VersiCharge Ultra 175™ | Installation Manual
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CRITICAL
Tightening Torque:
30 Nm / 22 lb-ft
Wire and commissioning
Note: For all field wiring terminal connections, refer to the
wiring diagram sticker on the reverse of the access hatch cover.
2. Single-phase power
The single-phase, power field wiring terminals are located on
the underside of the top-left section of the wiring access hatch.
Refer to the wiring diagram on the back of the access hatch
cover, or wire into the terminal blocks as follows:
Strip and crimp the single-phase wires before connecting to the
appropriate terminals. Once installed, perform a pull-test to
ensure that the terminations are secure.
CRITICAL
If the single-phase wiring is run in a three-core cable (2C+E),
do not terminate the third core (earth) to the common
grounding terminal (green and yellow). This wire must be
terminated to terminal block 4.
If not installed correctly, it will prevent the IMI from
adequately monitoring the site earth.
3. Safety loop
The two safety loop terminals are located on the tilt-switch PCB,
located on the bottom-right section of the wiring access hatch
(push to fit). Polarity is not critical for these wires.
Tilt switch wiring
1: Safety loop
2: Safety loop
Installation Manual | VersiCharge Ultra 175™
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12
Terminal blocks
34
1: Line
2: Neutral
4: Earth reference

Ethernet port access
The Ethernet port is situated on the front of the enclosure box.
Twist to disengage the base cap and wire in the Cat 6a STP
Ethernet cable.
Ensure the base cap is securely fitted back into the holder for
IP65 protection.
CAUTION
To ensure the stability of communication to the unit, it is
important that when terminating the network cable, the
shield is Earthed appropriately to the terminal.
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Fiber optic access
If fiber is to be utilized, then a fiber optic interface module is
required.
If this is the case, the fiber optic module shall be mounted at
the bottom of the unit.
The fiber optic interface module plugs into the Ethernet port of
the unit.
Ensure that the coupling ring is tight, so that when the fiber
optic cable is connected, the connection is tight.
For detailed wiring instructions, see reference.
Installation Manual | VersiCharge Ultra 175™
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Closing checklist
Follow these steps in order to ready the unit for commissioning:
1. Remove lifting straps
Carefully remove the lifting straps from the top slots in the
plastic.
2. Attach enclosure access cover
Check that the gasket has not been damaged or soiled. Use the
4mm Allen wrench to attach the enclosure access cover screws.
3. Attach the rear lower panel
Lift the panel, slide it over the fixing points and rubber cable
flanges on both sides until it is secure under the top panel, and
flush against the enclosure.
Use the 5mm Pin Hex tool to fasten the screws on both sides.
Do not over tighten.
CAUTION
If using a power drill to fasten the nuts, ensure the correct
torque setting of not greater than 2.0 Nm / 17.7 lb-inch. If
using a hand tool, fasten until resistance felt. Do not over
tighten.
Over tightening may result in damage to the screws and/or
gasket, reducing the effectiveness of the seal. This can
compromise the interior protection rating of the enclosure.
VersiCharge Ultra 175™ | Installation Manual
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Closing checklist
4. Plug in the parking sensor
The VersiCharge Ultra 175 unit has a parking sensor available for
use on the front, lower panel.
Unclip the parking sensor plug from the front, metal panel and
plug into the parking sensor.
Note that the plug for the parking sensor is located inside and
under the central edge of the front panel.
Screw the plugs together to ensure the IP65 seal.
5. Attach the front-lower panel
Raise and slide the front-lower panel into the fixing points
located under the front panel.
Fasten with nylon washers and security screws both sides,
using the 5mm Pin Hex tool.
Do not over tighten.
The VersiCharge Ultra 175 unit is now ready for commissioning.
Installation Manual | VersiCharge Ultra 175™
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Notes:
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