Siemens VersiCharge Ultra 50 User manual

usa.siemens.com/versicharge
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Installation Manual
VersiCharge Ultra 50™
50 kW DC fast charger

2

Table of Contents
Important safety instructions and specifications. Save these instructions 4
FCC Notice 6
Packaging, handling and receipt 7
Site configuration 8
Underground power preparation 12
Above ground power preparation 13
Installation requirements and equipment 14
Unpacking and installation preparation 15
Installation 18
Underground conduit and wiring 20
Above ground conduit and wiring 22
Wire and commission 23
Ethernet port access 25
Closing checklist 26
3

Grounding instructions
This unit is to be connected to a grounded, metal, permanent
wiring system; and an equipment-grounding conductor is to
be run with circuit conductors and connected to equipment-
grounding terminal or lead on battery 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 Ultra 50 fast charger.
Wiring size
3ø: 4 AWG
Use 90°C Copper Wire
Use 4 AWG insulated
grounding conductor
1ø: 18 AWG
Use 90°C Copper Wire
An insulated grounding conductor that is identical in size,
insulation material and thickness to the grounded and
ungrounded branch-circuit supply conductors except that it is
green with or without one or more yellow stripes is to be
installed as part of the branch circuit that supplies the unit or
system. This grounding conductor is to be grounded to earth
at the service equipment or, when supplied by a separately
derived system, at the supply transformer.
Important safety instructions and
specifications. Save these instructions.
This manual contains important instructions for the VersiCharge
Ultra 50™ electric vehicle fast charger model:
US2:VSCULT50SAG, 50kW DC
These instructions must be followed during installation of the
unit.
For charger operating instructions, see US2:VSCULT50SAG
Operating Manual (document SIDS-T40046-00-4AUS).
For charger maintenance instructions, see US2:VSCULT50SAG
Maintenance Manual (document SIDS-T40047-00-4AUS).
Identifying symbols
CAUTION
RISK OF ELECTRIC SHOCK
Equipment Grounding Conductor Symbol
øPhase Symbol
∿Alternating Current Supply Symbol
CAUTION
The Ultra 50 fast charger must be installed and serviced
only by qualified electrical personnel. To achieve EMC
compliance, the chassis of the Ultra 50 must be grounded
to the earth locally at the charger.
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.
VersiCharge Ultra 50™ | Installation Manual
4

Important safety instructions and
specifications. Save these instructions.
Input:
3ø WYE CONNECTED
277/480V ±10%
60Hz
55kW
1ø, 120V
60Hz
250W
The Ultra 50 must be connected to a circuit provided with an
appropriate branch circuit over-current protection in
accordance with the National Electrical Code, ANSI/NFPA 70.
Tightening torque:
Wiring terminals:
Breaker 4.0 Nm/35 lb-in
Service hatch:
2.0 Nm/17.70 lb-in
Operating temperature:
-35° to 50°C / -31° to 122°F
Maximum ambient
temperature:
55°C /131°F
Weather rating:
NEMA Type 3R
Installation Manual | VersiCharge Ultra 50™
5

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 in which case the user will be required to correct
the interference at his own expense.
Modification warning
(FCC Part 15.21)
In addition, the user’s manual or instruction manual shall
caution the user that changes or modifications not expressly
approved by the party responsible for compliance could void the
user’s authority to operate the equipment (see below for
example).
Warning: Any changes or modifications not expressly
approved by (Siemens Industry, Inc.) could void the user’s
authority to operate this equipment.
VersiCharge Ultra 50™ | Installation Manual
6

Packaging, handling and receipt
Read these instructions carefully to become familiar with Ultra
50 packaging and handling procedures prior to unpacking and
installation.
In all cases, the Ultra 50 is to be transported to the installation
site in its original packaging and only unpacked at the
installation site.
Installation, commissioning and servicing of the Ultra 50 should
only be carried out by qualified personnel.
Materials:
The Ultra 50 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.
Storage temperature:
-20 to 45°C / -4 to 113°F.
Handling:
Only lift the Ultra 50 packaging to 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
Ultra 50 is not damaged.
If there are any problems noted, make a formal complaint to the
carrier and notify your supplier.
Packed crate weight:
200kg/440lb
Crate size:
850(W) x 2150(H) x 450(D)mm
33.5(W) x 84.5(H) x 18(D) inches
Ultra 50 size:
750(W) x 2000(H) x 330(D)mm
29.5(W) x 78.7(H) x 13(D) inches
(without plugs)
Ultra 50 weight:
165kg/364lbs
Installation Manual | VersiCharge Ultra 50™
7

Site configuration
Site survey:
The Ultra 50 can be installed onto a newly prepared concrete
pad, or onto an existing concrete surface, with service wiring
supplied through conduit via the foundation or above ground.
If a foundation to supply power from underground is to be
prepared, follow the underground power instruction for
installation.
If the charger is to be installed onto an existing concrete surface,
follow the above ground power instruction for installation.
The Ultra 50 is best installed following the recommended site
configuration requirements.
Ground fixing:
The Ultra 50 is to be fixed to the ground through the baseplate
fixing holes with 4 x M16 or 5/8-11 inch fasteners (not supplied).
The fasteners should fix the Ultra 50 securely to the foundation
through the baseplate and protrude 30-40mm/1.2-1.6 inch
maximum from the foundation surface, in accordance with the
dimensions and fixing points shown in: Figure 5: Fixing guide.
See Figure 1: Dimensions walls or obstacles, for installation
against or near walls or other obstacles.
Foundation requirements:
The foundation must be flat, even, and the appropriate density
for the weight of the Ultra 50.
Check the flatness and level of the foundation and level of the
Ultra 50 baseplate prior to fixing.
Communications:
4G network capability or Ethernet.
The Ultra 50 is fitted with a Harting external IP65 rated Ethernet
port. This port can be accessed temporarily during installation.
If a more permanent, sealed connection is required, use Harting
external Ethernet connector, 9153000401. See page 23 for
Ethernet port access.
Site restriction:
Installation shall not be done in a commercial garage (repair
facility) or closer than 6 meters/20ft of an outdoor motor fuel
dispensing device.
CAUTION
A qualified engineer must survey the installation site to
determine the correct ground preparation for the size and
weight of the Ultra 50, in accordance with all local applicable
codes and regulations.
VersiCharge Ultra 50™ | Installation Manual
8

Site configuration
Minimum measurement
requirements:
Contact your Siemens representative for installation advice, if
your mimimum measurements are smaller than shown in
Figure 1.
28.5” (725)
minimum
6.3”
160
9.8”
(250)
11.8”
(300)
Do not scale
Wall Wall
28.5” (725)
minimum
Figure 1: Dimensions walls or obstacles
Installation Manual | VersiCharge Ultra 50™
9

Site configuration
Ultra 50 charging cable range:
The standard Ultra 50 cable reach is approximately 2.0
meters/6.5 feet as shown in these site layouts.
Customized lengths are also available. Contact your supplier
should your requirements differ.
If longer length cables are used, please ensure the cable is kept
tidy and close to the Ultra 50 sides at all times.
Single carparking bay:
To service one car bay, 500mm/20 inches of space is
recommended between the car and the Ultra 50 front and back
for ease of use.
Wheel stops installed at 1200mm/4 feet from the center-front of
the Ultra 50 can achieve this.
If the Ultra 50 is to be installed with it’s back or sides against, or
near a wall or other obstacle, use the minimum distances
shown in Figure 2.
Top view
Do not scale
20”
(500)
SAE Combo
Plug Range
CHAdeMO
Plug Range
47”
(1200)
WHEEL
STOPS
Figure 2: Single car parking minimum distances
VersiCharge Ultra 50™ | Installation Manual
10

Site configuration
Site configuration back-to-back units:
When being installed back to back, a minimum distance of
300mm/12 inches between the Ultra 50 chargers is
recommended.
To ensure this minimum distance is observed, use the
dimensions for foundation positioning in Figure 3.
30.3”
(72)
2.7”
(68)
6.3”
(160)
16”
(410)
11.8”
300
Do not scale
6.3”
(160)
30.3”
(72)
2.7”
(68)
Site configuration servicing:
An additional space of 700mm/27.5 inches from the center-
front of the baseplate is required to open the front panel for
servicing, as shown in Figure 4.
Do not scale
27.5”
(700)
Figure 3: Back to back units Figure 4: Servicing distance requirement
Installation Manual | VersiCharge Ultra 50™
11

Underground power preparation
If a concrete foundation is being prepared to bring power into
the Ultra 50 through the baseplate, use the following as a guide
for preparation.
Use the Ultra 50 template (supplied in the crate kit) or measure,
as per Figure 5, to ensure the fixing points are correct.
Locate mounting studs and conduit within 0.05” (1.25mm)
tolerance.
Foundation power hole:
When preparing the concrete foundation, a 1-1/4” NPT female
coupling (not supplied) is to be inserted flush with the top
surface of the concrete pad, and precisely located in the 50mm
power hole location in relation to the mounting studs. This
ensures the sealing of the supplied Flexa conduit system into
the foundation.
Fixing points:
Use 4x 5/8-11 studs, protruding 1.2-1.6 inches above the surface.
If the studs protrude more than this, it will be impossible to
remove and replace the radiator if required.
Ethernet cable hole:
If hardwiring in the Ethernet, use this hole for the cabling.
50mm power hole
Fixing point holes
Ethernet cable hole
Figure 5. Mounting reference.
6.3”
(160)
ULTRA 50 FRONT
11.8”
(300)
2.8”
(72)
2.7”
(68)
1.0”
(26)
2.1”
(53)
1-1/4” NPT
Female coupling
top to be flush
w/surface
Do not scale
4x 5/8-11 studs
Protruding 1.4”
± 0.2” above
the surface
3.4”
(86)
2.5”
(63)
70mm power hole
2.3”
(60)
1.6”
(40)
Grounding rod hole
Figure 5: Mounting reference
VersiCharge Ultra 50™ | Installation Manual
12

Above ground power preparation
If power via conduit is being supplied to the Ultra 50 above
ground, the conduit will enter the Ultra 50 via the back radiator
panel on the left-hand side, as shown in Figure 6.
Use the Ultra 50 template (supplied in the crate kit), or measure
as per Figure 5, to ensure the fixing points are correct. Locate
mounting studs and conduit within 0.05” (1.25mm) tolerance.
To ensure the correct seal is maintained into the Ultra 50, only
use Flexa 1-1/4 inch ROHRflex conduit, order code 0237.202.036
(not supplied) to bring power cabling into the Ultra 50.
Leave at least 1 meter/3 feet of power cabling from the back-left
fixing point, for installation as shown in Figure 7.
Prior to installation the conduit and wiring will require
trimming.
Fixing points.
Use 4 x 5/8-11 studs, protruding 1.2-1.6 inches above the
surface. If the studs protrude more than this it will be
impossible to remove and replace the radiator, if required.
Ethernet cable hole:
If hardwiring in the Ethernet, use the hole referenced in
Figure 5.
Figure 6
Top view
1 meter/3 feet
Not to scale
Back
left
fixing
point
Figure 7
Installation Manual | VersiCharge Ultra 50™
13

Installation requirements and equipment
These instructions provide a systematic guide for installing
and commissioning the Ultra 50.
The Ultra 50 must be installed and serviced by qualified
electrical personnel.
Observe all pertinent national, regional, and local safety
regulations when you install and commission the Ultra 50.
The Ultra 50 has a NEMA Type 3R 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.
Installation shall not be done in a commercial garage (repair
facility) or closer than 6 meters/20ft of an outdoor motor fuel
dispensing device.
The Ultra 50 must be properly installed, assembled and
commissioned according to these instructions before it is
used. Prior to installation contact your supplier to organise
commissioning information.
Supplied with Ultra 50:
5mm pin hex tool to remove the M8 security screws fixing the
plastic panels.
2.5mm hex ‘L’ wrench
Lifting straps
Blanking plugs are fitted for transport and storage.
Flexa conduit system
Black ferrite ring ID13x40mm
Black ferrite ring ID25x43mm
Grey ferrite ring
Baseplate template
The Ultra 50 is shipped with a temporary, single-phase power
cable which allows the unit to be powered prior to
installation. This allows for software updates, charger
configuration and/or 4G connectivity testing. The cable has a
male IEC socket and an IEC female lead is required to supply
power.
If pre-installation power up is required, contact your supplier
prior to the installation date to synchronize with Siemens.
Required equipment:
Lifting apparatus. See pg 4 for weights. Ensure lifting apparatus
is sufficiently rated.
For height restricted areas alternative lifting methods are
available. Contact your supplier for more information.
4x M16 or 5/8 glavanised or SS washers
4x M16 or 5/8-11 galvanised nuts to match fasteners.
Flexa PN 0237.202.036 conduit (above ground power
installations only).
Tools:
Socket set & ratchet or adjustable spanner.
Allen keys or socket set hex bits.
Power driver
Sockets required:
8mm for radiator removal and service hatch removal.
10mm socket for earthing strap removal.
16mm for removal of shipping baseplate bolts.
Approved external sealant.
DOCUMENT KEY:
Items shown in orange are parts that require action for
that step.
VersiCharge Ultra 50™ | Installation Manual
14

Unpacking and installation preparation
1. Open crate
Move the crate as close to the prepared installation site as
possible. Ensure there is enough room to manuver the lifting
apparatus.
Remove/slide out all crate tubes to disassemble the cardboard
crate.
2. Lift Ultra 50 to vertical
Securely attach the lifting straps at the top of Ultra 50 to the
lifting apparatus and gently raise to a standing position on the
shipping baseplate.
The Ultra 50 must remain attached to the lifting equipment
until the mounting bolts have been installed.
NOTE: The Ultra 50 is 2050mm/6.72ft tall on the shipping
baseplate.
Do not use the plug holders to assist lifting the charger at
any stage.
Once upright, remove all wrapping.
.
Lifting Straps
Shipping
Baseplate
Installation Manual | VersiCharge Ultra 50™
15

Unpacking and installation preparation
3. Remove front and rear radiator panels
If access to the rear radiator panel is difficult, the internal
radiator may be removed to access the rear-base fixing points.
If so, remove the front radiator panel only and go to item 5.
Unscrew the 8x security screws and remove them and the
washers from both radiator panels using the 5mm pin hex tool.
Pull the radiator panels away from the metalwork frame to
remove.
4. Remove shipping bolts
Unscrew the 4x bolts from the shipping base to disengage.
16mm socket required.
Note: Keep the plastic inserts from the bolts for later use.
Removing the radiator from the base of the Ultra 50 gives more
space to bring power into the unit, however, removing the
radiator is not always required. Assess the situation on site.
5. Remove radiator (optional)
Unscrew the 4x nuts using an 8mm nut driver to remove the
radiator. Pull the radiator off the fasteners, and sit the radiator
on the base plate.
Reach behind and unclip the four-way connector.
The four-way connector is the left-hand plug attached to the
underside of the unit. Squeeze the front clip and pull down to
release.
VersiCharge Ultra 50™ | Installation Manual
16

Unpacking and installation preparation
The radiator cooling system must be disengaged from the unit.
Unclip the two quick-release parts. One is on the base behind
the radiator, the other is on the left side with the expansion
bag.
NOTE: Do not twist or pull on the tubing engaged with the
metal quick release parts. Pull on the metal parts to release, and
press the metal parts together to join.
Store the radiator in a safe place ensuring no damage to cooling
hoses for later re-assembly.
For the purpose of this manual, the following installation
pictures are shown without the radiator.
Installation Manual | VersiCharge Ultra 50™
17

Installation
1. Secure to foundation
Lift the Ultra 50 by the supplied lifting straps, place onto the
prepared foundation and secure with the specified fasteners.
Note: Use the plastic inserts you kept earlier in the baseplate
holes.
2. Remove fasteners from front panel
Remove the 6x security screws and washers from the front
panel using the provided 5mm pin hex tool.
3. Place front panel on ground
The front panel is attached to the enclosure with wiring and an
earthing strap on the front left-hand side.
Lift the front panel up to release from the top hook and gently
lower to the ground in front of the Ultra 50.
In calm conditions, it may be possible to keep the front panel
connected during commissioning. If this is possible, go to page
17, item 5.
If in doubt, disconnect the front panel (see pg 17, item 4) and
store in a safe place until the unit is ready to close for use.
VersiCharge Ultra 50™ | Installation Manual
18

Installation
4. Disconnect front panel
There are three points to disconnect:
1. Wiring to the top, rear panel.
Squeeze the connector to disconnect.
2. Earthing strap.
Unscrew the nut on the metalwork with a 10mm socket.
Remove the nut and earthing strap lug from the stud.
3. Connector ‘B’ on the HMI panel.
Connector ‘B’ detaches by squeezing the connector front and
rear with your fingers and pulling down.
5. Remove service covers
To prepare the wiring for the VersiCharge Ultra, remove the
service hatch and cover to allow access to the internal
enclosure. Use an 8mm socket and 2.5mm hex bits.
The Service Hatch has an attached gasket. Ensure this is
carefully stored to avoid damage or accumulation of debris.
6. Pre-installation power up
The Ultra 50 is shipped with a temporary single-phase power
cable which allows the unit to be powered prior to installation.
This is attached to the M40 blanking plug. This allows for
software updates, charger configuration and/or 4G connectivity
testing.
The cable has a male IEC socket and an IEC female lead is
required to supply power.
If pre-installation power up is required, contact your supplier to
synchronize with Siemens.
7. Remove IEC cable wiring
Remove the M40 blanking plug and IEC cable wiring from the
switch gear.
1
2
3
EXPLODED VIEW
Service
Cover
Service
Hatch
FRONT VIEW
Installation Manual | VersiCharge Ultra 50™
19

Underground conduit and wiring
The Ultra 50 is supplied with a Flexa conduit system in the crate
kit, with all parts attached.
1. Disassemble the Flexa system
Detach all pieces of the system below the conduit. The flex
adapter is removed by pushing in the adapter ring, and pulling
out the conduit.
2. Fit Flexa system into base
Install the 6” conduit nipple, conduit coupling and flex adapter
into the embedded 6” coupling (not supplied) in the
foundation, using sealant on all threads.
6” conduit
nipple
conduit
coupling
flex
adapter
flexa
conduit
flex
adapter
washer
locking
ring
Push in ring
Pull out conduit
VersiCharge Ultra 50™ | Installation Manual
20