Tritium Veefil-RT 175-S User manual

©2020 Tritium Pty Ltd
Brisbane, Australia
http://www.tritium.com.au
Installation Manual
Veefil-RT 175-S Site Installation
TRI125.INS.018
4 March 2020
Version 1

Veefil-RT 175-S Site Installation Manual
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4 March 2020
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Contents
1Overview..................................................................................................................................3
1.1 Purpose of this document.........................................................................................................3
1.2 Disclaimer and warranty...........................................................................................................3
1.3 Specifications ...........................................................................................................................3
1.4 Installation safety considerations .............................................................................................3
1.5 Acronyms and abbreviations....................................................................................................4
1.6 References and related documents .........................................................................................5
2Site plan...................................................................................................................................5
2.1 Block diagram...........................................................................................................................5
2.2 Layout.......................................................................................................................................6
3Resources ...............................................................................................................................7
3.1 Tools and consumables ...........................................................................................................7
3.2 Heavy equipment .....................................................................................................................8
3.3 Torques utilised during installation...........................................................................................8
4Installation...............................................................................................................................9
4.1 Conduit and cabling..................................................................................................................9
4.2 Upstream protection.................................................................................................................9
4.3 Earthworks................................................................................................................................9
4.4 HPC equipment storage recommendations and conditions...................................................10
4.5 High power electrical connections..........................................................................................11
4.6 Integrated power unit installation............................................................................................12
4.7 User unit installation...............................................................................................................19
5Site installation handover....................................................................................................24
5.1 Pre-checks..............................................................................................................................24
5.2 Polarity, cross-wire and bolted short test ...............................................................................24
6Revision record ....................................................................................................................25

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1 Overview
1.1 Purpose of this document
The purpose of this document is to provide qualified electrical engineers and Tritium
Certified installers with an outline of the steps required to install a Veefil-RT 175-S high
power charging 175kW site.
This document is for both the single and dual cable variants of the Veefil-RT 175-S.
Note: The images used in this document are of the dual cable variant.
1.2 Disclaimer and warranty
This Manual sets out Tritium’s understanding of best-practice methodologies and its
requirements for installation of the Veefil-RT 175-S and is provided to customers pursuant to
the same terms and conditions under which Tritium has supplied its products.
Tritium encourages all owners of its products to consult a qualified engineering consultancy
firm to provide independent advice on the methodologies set out in this manual, and site
design requirements, including in relation to applicable regulatory and statutory
requirements. All site designs must be signed off on by a professional engineer.
Tritium accepts no liability for any loss caused, whether due to negligence or otherwise
arising from the strict adherence to the requirements set out in this manual in contravention
of local regulatory and legal requirements.
It is an express condition of Tritium’s manufacturer warranty that:
•the requirements set out in this manual are adhered to (subject to local regulatory and
legal requirements) when installing the Veefil-RT 175-S; and
•that the installation is conducted by a Tritium Certified technician who has completed
Tritium’s installation training course for the Veefil-RT 175-S.
1.3 Specifications
Unit
Specifications
LV Distribution Board
•185kVA Output per charger
•400V/300A 50Hz, 480V/250A 60Hz, 600V/200A 60Hz
•UL listed circuit breakers with optional under-voltage relay
•Maximum available fault current of 18kA (current limiting fuses or
current limiting circuit breakers may be required to maintain limit
of 18kA)
•Residual current monitoring device of time delay type (optional)
Power unit
•1 x 185kVA double insulated safety isolation transformer
•1 x 175kW AC/DC converter with AC contactors
•Integrated Communications Unit, Dual 4G SIM
•800kg
User unit
•1 x 175kW 350A DC/DC converter (CCS/CHAdeMO)
•260kg
1.4 Installation safety considerations
•First Aid Kit
•Low Voltage Rescue Kit (LVR Kit)
•Defibrillator
•Never walk under suspended loads

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•Site shall never be worked on while electrically live. Before any duty, ensure LV
distribution board circuit breakers are isolated and locked out.
•Fencing and exclusion zones, authorisation from the local authorities.
•Exclusion zones when lifting hardware
•Shelter from weather (sun, wind, dust, and rain)
•Second person in the event of an accident
1.5 Acronyms and abbreviations
Acronym/abbreviation
Definition
IPU
Integrated Power Unit.
UU
User Unit
DMM
Digital multimeter
CU
Communication Unit
UV
Undervoltage
Veefil RT175-S Solution
TRI125-175 - Tritium 175kW RT175-S Veefil Solution
Comprised of a single IPU and a pair of UU.

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1.6 References and related documents
•TRI125.INS.016 Veefil-RT 175-S Piping and Cabling
•TRI125.CHK.008 Veefil-RT 175-SK System Installation Checklist
2 Site plan
2.1 Block diagram
Figure 1: Single charger block diagram

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2.2 Layout
Figure 2: Site electrical layout

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3 Resources
3.1 Tools and consumables
3.1.1 Tools
•Network Termination Equipment
•Electric Hydraulic Cable Lug Terminator
•100m hook-up wire
•Rags
•Electric caulking gun
•Drill
•Torque Wrench
•Step ladder
•Table
•Chair
•General tools:
•Spanners
•Shifters
•Socket Set >24mm
•Screwdrivers
•Side cutters
•Allan Keys
•Knife
•Multi grip pliers
3.1.2 Consumables
Ensure that the appropriately sized cable termination lugs for the AC and DC installation
wiring are procured, as well as the required heat-shrink to demark three phase AC cabling,
high powered DC cables, and protective earth cables.
CID
Description
QTY
12942 OR
12943
RT 175-S Installation Kit (CID is region dependent).
Note: Does not contain any DIN standard lugs
-
5542
UL Listed CABLE TIE, Yellow, 100X2.5MM, PK100
200
6234
UL Listed CABLE TIE, 94V-2, 292MM x 4.8MM BLACK, PANDUIT,
PK100
1
8405
Cable Ties, Black, 450 x 8mm, Heavy Duty, 100 pack
1
9543
Nofirno cable sealant
-
9127
Cat 6A 10G Shielded Keystone SLIMLINE Jack. Toolless 180 degree IDC
2
9416
Cat 6A S/FTP LSZH 1.5m RJ45-RJ45 Network Cable: Blue
2
9565
Molex 44915 Series Number Cat6 8P8C Way Cable Mount RJ45 Modular
Plug Male
2
5792
EJCC Copper Jointing Compound
125 ml
2567
Aluminium jointing compound
125 ml

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3.2 Heavy equipment
•Crane –with 7m reach, 1T lift capacity
•Forklift
•Temporary weather shelter
3.3 Torques utilised during installation
Equipment
Thread code
Position
Torque (Nm)
User Unit (UU)
M5
Hatch cover
2
M8
Ground
16
M8 Post hex
Plastic cover
4
M10
DC
30
M12/16
Chassis mount
30/40
Integrated
M10
DC
30
M10
AC, Ground
30
M12
Chassis mount
30

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4 Installation
4.1 Conduit and cabling
Important
Prior to installation of the piping and wiring, a professional review of local requirements
must be performed to ensure that laws and regulations are adhered to. As a result, it may
be required to deviate from the requirements of this documentation.
Refer to TRI125.INS.016 Veefil RT175-S Piping and Cabling.
Site electrical design must be carried out and approved by a suitably qualified professional.
Prior to commissioning, the electrical installation must be signed off as safe, complete and
compliant to local laws and regulations.
4.2 Upstream protection
4.2.1 Device selection
Maximum sizes for the upstream electrical protective equipment supplying the RT 175-S IPU
are as described in the following table.
Electrical Network
RT175-S Maximum
Demand
Recommended Size
Maximum Size 2)
600 VAC 3ph, 60Hz
200 A
250 A 1)
250 A
480 VAC 3ph, 60Hz
250 A
320 A 1)
320 A
400 VAC 3ph, 50Hz
300 A
320 A
350 A
1) Recommended sizes for North American markets are selected according to NEC article
625, accounting for the 125% rule.
2) The over current protection device rating must not exceed these values in order to maintain
primary protection for the LV transformer within the IPU.
Important
Available short-circuit fault current for the RT175-S must not exceed 18 kA. This means that a current limiting fuse
or circuit breaker may be required in locations where site fault current availability exceeds this value.
4.2.1 Optional under-voltage relay
The IPU includes pre-wired terminals to allow the optional use of an under-voltage device at
the upstream supply breaker. The pre-wired terminals supply a normally closed 230VAC
signal to allow upstream isolation in the event of a RT175-S safety loop trip (for example, tilt
switch, cabinet door switch).
The use of an upstream under-voltage trip is optional, as the IPU locally isolates via the input
contactor in each of these events.
4.3 Earthworks
Ensure that earthworks and trenching is completed with respect to installation personnel
safety and applicable local and national legislation.
Ensure that all trenches are adequately roped off or barricaded to prevent accidental access
and take care with respect to trenching locations and timing to allow appropriate access to
equipment as required.

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4.4 HPC equipment storage recommendations and conditions
Ensure that equipment is stored properly on site to ensure that it is protected from the
weather and not exposed to the rain. Packaging may be damaged when wet.
When storing equipment:
•Stack and protect boxes inside a fenced off area of the site.
•Protect from weather conditions; store in a dry place or cover with a waterproof
tarpaulin.
•Storage temperature -20 to 45 ºC.
•Ensure that only packing crates of similar sizes are stacked.
•Ensure a maximum height of two crates.
•Cabinets must be closed when leaving the site.
Figure 3: Maximum stacking height of similar sized boxes.

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4.5 High power electrical connections
It is critical that the high-power electrical connections are done correctly to ensure safe,
compliant, and warranted performance of the charging equipment.
SAFETY WARNING!
Only trained and competent electricians are authorised to perform this work.
•Ensure that the upstream power feeds are off and locked out throughout the work.
•The charging equipment must not be energised at any time during the installation. To
ensure personnel and equipment safety, power will be applied for the first time during
the commissioning phase.
•Ensure that the cables used meet the minimum requirements specified by Tritium.
•Ensure that the lugs are compatible with fine strand cable, and that the crimping die is
correct for both the wire type and lug type.
•Double check lug, cable, and crimp die compatibility.
Figure 4: F type die from Klauke
•A small amount of copper jointing compound must be applied to the contact patch of all
lug to copper busbar connections. This inhibits corrosion at the joint to maintain a good
connection for the life of the charging system.
•Use a flat washer in contact with the top of the lug and a spring washer on top of the flat
washer for all bolted lug connections.
•Torque all connections to the specified amount and mark the torque with a paint pen
immediately.
•Clearly label all cables. Relabel when a cable is shortened, if required.
•Mark all cables with colour coded heat shrink.
•Do not cover the entire lug with heat shrink; leave one crimp mark showing so that the
correct crimping tool stamp is shown.

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4.6 Integrated power unit installation
4.6.1 Access and clearance
To maintain accessibility and serviceability of the unit via the cabinet doors, the front and
rear of the IPU should be spaced at least 1m from any walls. This also aids in ventilation of
the units.
If the IPU cabinets are required to be serviceable to the point where the primary IPU
transformer may be removed in future, make allowancefor enough spacing between the rear
of the unit to fit the length of a forklift and associated lifting tines, with additional appropriate
manoeuvring space.
4.6.2 Foundation - precast preparation
Foundation design and preparation is the responsibility of the customer. Device footprints
are provided by Tritium for hole drilling and conduit/cable location guidance.
For a full-scale drawing of Figure 5 and Figure 6, see the following documents respectively:
•TRI125-284_Foundation Template
•TRI125-285_Cable Entry Diagram.
Note: A mounting stencil may be supplied by tritium at customer request. All lengths in the
below figures are specified in millimeters.
Figure 5: IPU Foundation Template

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Figure 6: IPU Cable Entry Diagram
After the foundation is prepared:
Ensure that all cables are pulled and labelled correctly according to the cabling plan.
Note: For more information, see TRI125.INS.016 Veefil-RT 175-S Piping and Cabling.
Cut the mounting rods down to 50mm above the foundation ground.
Deburr, then straighten threads.
Clean the slab of dust and debris.
Apply anti-seize to rods and temporarily fasten with an M12 Nut and flat washer.

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4.6.3 Unbox and install the IPU
Locate the IPU box that is specially marked and contains the set of lifting eyes and
straps.
Remove the top and side cardboard panels.
Open the lifting kit and attach the M12 load-rated lifting eyes (1.2 Tonne), lifting slings,
and protective pads to the four lifting points located in each corner on top of the cabinet.
Use a torque wrench to tighten the lifting eyes.
Note: Use recommended torque settings when fastening lifting eyes; the settings are
written on the parts.
Figure 7: View of lifting slings attached to the unit
Carefully crane the IPU into place, bolt the IPU down, then detach the crane.
Important: Ensure that the IPU is properly secured by the bolts before you detach the
crane.

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4.6.4 Terminate the IPU unit DC link
Important
Prior to installation of the piping and wiring, a professional review of local requirements must be performed to
ensure that laws and regulations are adhered to. As a result, it may be necessary to deviate from the cable lug
sizes (and corresponding cable sizes) referenced in this section.
Identify the DC output cables for the rectifier pack of the power unit.
Note: These are contained within conduit B as shown in TRI125.INS.016 Veefil-RT
175-S Piping and CablingError! Reference source not found..
Measure, cut, and crimp with M10 cable lugs to the DC mounting points.
Figure 8: IPU DC Output Terminals
Measure, cut, and terminate the UU Earth with an M10 cable lug to the second terminal
of the IPU earth bar.
Figure 9: IPU Earth Terminals, UU Connection Point

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4.6.5 Terminate the IPU AC link
Identify the AC input cables.
Note: These are contained within conduit A as shown in TRI125.INS.016 Veefil-RT
175-S Piping and CablingError! Reference source not found..
Measure, cut, and crimp with M10 cable lugs to mounting points L1, L2, L3 on load
break switch Q0, located on the bottom-left of the main gear tray.
Figure 10: IPU 3phase AC Input isolation switch (Q0)
Measure, cut, and crimp the protective Earth with an M10 cable lug to mounting point
GNDAC1 on the bottom of the gear tray.
Figure 11: IPU Earth Terminals, Earthing Electrode Connection Point
L1
L2
L3

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4.6.6 Terminate Earthing electrodes
Important
•For EMC compliance, it is important that a local Earthing electrode is used to bond the chassis of the IPU
directly to ground. This may be in the form of an earth stake, or if available, can be bonded to pre-existing
buried earth structures.
•Prior to installation of the unit, a professional review of local lightning protection requirements must be
performed to ensure that laws and regulations are adhered to. As a result, it may be necessary to install
additional earthing electrodes for outdoor installations.
Terminate the bandeizen/earth electrodes to the IPU earth busbar as shown in section 4.6.5
Terminate the integrated power unit DC link. If metal foundation plates are used, terminate to
each IPU chassis or earth busbar.
4.6.7 Terminate low power and data cables
All low power field wiring (excluding communications) to the user unit is to be terminated into
terminal block X1 (Figure 12).
Note: IMI earth reference field wiring terminal is not depicted in in the following image.
Figure 12: IPU Terminal Block X1 –Red highlights showing customer field wiring. Yellow highlights show optional
wiring.

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Strip, bootlace (only if stranded wire, skip bootlace if solid core), and insert the wires
into the field wiring terminals as follows:
Terminal
Wire
2
•User Unit 230 VAC Neutral
7
•User Unit 230 VAC Line
18
•User Unit 24V Safety Loop
19
•User Unit 24V Safety Loop
22
•IMI Earth reference (from supply)
•IMI Earth reference (to user unit)
11
•(optional) upstream breaker shunt
output, 230 VAC Line
4
•(optional) upstream breaker shunt
output 230, VAC Neutral
Locate the Ethernet cable from the control shelf and use the tool-less jack from the
installation kit to terminate the Cat6A cable.
Note: Use colour code A for all Cat connections.
Cover the Ethernet jack in heat shrink and secure to the frame of the IPU.
Connect a 1m patch lead from the Ethernet jack to the control shelf.
Note: Alternatively, terminate the cable directly with a male connector and insert this
into the control shelf.
Figure 13: Cat6A tool-less, Example Ethernet Terminations

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4.7 User unit installation
4.7.1 Foundation preparation
Note: If the user unit is to be located a distance greater than 100m from the IPU, optical fibre
is required for communication in place of Cat6a.
Foundation design and preparation is the responsibility of the customer. Device footprints
are provided by tritium for hole drilling and conduit / cable location guidance. For further
details, please refer to TRI125.INS.001 Veefil-RT175-S User Unit Installation Manual.
Note: A mounting stencil may be supplied by tritium at customer request.
Figure 14: User Unit Baseplate Dimensions
Ensure that all cables are pulled and labelled correctly.
Ensure that conduits are cut to 70mm from the foundation ground.
Cut the M16 mounting rods down to 50mm from the foundation ground.
Note: Do not use less than M12.
Clean the foundation of any debris.
Inspect the mounting rods to ensure they are straight, and the threads are clean.

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Figure 15: Completed User Unit Foundation Preparation
4.7.2 Unboxing and craning
Remove the lid and walls from the shipping box.
Note: For more information, see TRI125.INS.019 Veefil-RT 175-S User Unit Installation
Manual.
Figure 16: User unit lifting points (indicative)
Attach lifting straps to the crane.
Slowly lift the user unit until clear of the ground.
Quality reminder
Be careful as the unit may swing. A second operator may be required to control the user unit lift.
Lower the unit to the ground in a vertical position, using the crane to keep tension.
Remove the protective plastic wrapping from the lower portion of the user unit
Remove the screws that hold the front lower panel.
Remove the front lower panel and store in a safe location to prevent damaged or
scratching.