TPS Velox i Customer's Manual
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TPS Velox i Customer's Manual

Ultra rapid ev charger
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THE POWER OF TOMORROW. TODAY.
Velox i
Ultra Rapid EV Charger (EVC)
Customer Manual
CM1-1

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Summary of Contents for TPS Velox i

  • Page 1 THE POWER OF TOMORROW. TODAY. Velox i Ultra Rapid EV Charger (EVC) Customer Manual CM1-1...
  • Page 2 KEEP SAFE FOR FUTURE REFERENCE The contents of this Customer Manual are subject to recurring updates and modifications, as the Velox i Ultra Rapid EVC undergoes regular reviews for improvements. Before any use, please check and download the latest revision of the Customer Manual using the QR code or hyperlink below to stay informed about any future changes.
  • Page 3 Copyright © [2024] All rights reserved. The information contained in this document is proprietary to Turbo Power Systems Limited (“TPS”). By accepting this document, the recipient agrees to protect its contents from further dissemination. The recipient may within its organisation use such information only as is permitted for the necessary evaluation of the information.

  • Page 4: Table Of Contents

    8.2. PERFORMING A HARD RESET OR FULL POWER CYCLE ................ 35 END OF LIFE DISPOSAL OF THE VELOX I ULTRA RAPID EVC OR COMPONENT PARTS ....... 36 10. DOCUMENT HISTORY ............................. 36 11. APPENDIX A – VELOX I ULTRA RAPID EVC – OUTLINE DRAWING ............37 12.

  • Page 5: General Information

    Before contacting TPS, please ensure you have the serial number of your Velox i Ultra Rapid EVC to hand. Details of where to find the serial number are in section 3.4 of this manual. The serial number must be quoted in all communications with TPS.

  • Page 6: Acronyms And Abbreviations

    Vehicle to Everything 1.4. Figures It is not always possible or practical to show the exact configuration of your Velox i Ultra Rapid EVC. Any figures used within this document are indicative and are for instruction and description purposes only.

  • Page 7: Safety

    Safety 2.1. Safe Working Practices WARNING 1. Only suitably trained and authorised personnel should be allowed to work on this EVC. 2. This EVC uses high voltage: all possible steps must be taken to maintain safety of the personnel and any staff working near the EVC at all times. 3.

  • Page 8: Safety Precautions To Consider When Working On The Velox I Ultra Rapid Evc

    The manufacturer (Turbo Power Systems) is not liable for any damages, losses, costs, expenses, or injuries incurred by any USER of the Velox i Ultra Rapid EVC, if such damages, losses, costs, expenses, or injuries occur as a result of failure to comply with all the instructions contained in this manual.

  • Page 9: Warranty

    2.5. Warranty As per the Supply of Goods and Services agreement between Turbo Power Systems and the OWNER, the goods supplied, and all products supplied shall: • Conform to the configuration specified and technical data, contained within section 3.3. • Be of satisfactory quality and fit for any functionality and purpose set out in the configuration specified and technical data, contained within section 3.3.

  • Page 10: Product Information

    Where grid capacity alone is sufficient for EV charging needs, Velox i Ultra Rapid EVCs can be used with a TPS Potenza LV Distribution Grid Inverter to simply provide a ‘hub and spoke’ charging system,...

  • Page 11: Technical Overview

    PLEASE NOTE: The Velox i Ultra Rapid EVC is primarily intended for use with TPS own Potenza LV Distribution Grid Inverter (DGI). If the application for which the EVC is intended requires its use with a non-TPS supplied DC interface unit, please contact TPS to discuss the details of this application, as variations to the contents of this manual may apply, and there may be an impact on the Warranty terms and conditions.

  • Page 12: Technical Data

    3.3. Technical Data Model Velox i Ultra Rapid EV Charger Max Rated output power 120 kW @ >600 V vehicle battery Max charge current 200A DC Supply voltage 775-825 VDC, with <5% ripple Nominal DC supply current 160 A AC Supply voltage...

  • Page 13: General Arrangement Of Velox I Ultra Rapid Evc

    Payment / RFID module Connectors: CHAdeMO / CCS Figure 3 - Velox i EVC Front and right-side views LED Charging Indicators Figure 4 - Velox i EVC Rear and left-side views PLEASE NOTE: The rating plate is located on left-side face. Always quote the unit serial number when contacting the TPS Product Support Team.

  • Page 14: Storage

    3.5.2. Longer Term Storage If the Velox i Ultra Rapid EVC is switched off for a period exceeding 6 months, an inspection will be needed before it can be switched back on. This must be carried out by TPS or an approved / trained person.

  • Page 15: Installation

    Installation PLEASE NOTE: The Velox i Ultra Rapid EVC must only be installed by Turbo Power Systems or a qualified Installation Engineer. The qualified Installation Engineer must: • Have a full working knowledge of the EVC and its safe installation.

  • Page 16: Velox I Ultra Rapid Evc Clearance Zone And Distance To The Potenza Dgi

    100 metres. If installation is to be in a closed building, the room in which the Potenza LV DGI and Velox i Ultra Rapid EVC will be located must have a system of permanent renewal of air.

  • Page 17: Unpacking The Velox I Ultra Rapid Evc

    Before beginning the unpacking process, please check the transport indicators as instructed in the Velox i Ultra Rapid EVC Quick Guide CM2-1, which accompanies the EVC. There are 2 types of indicators fitted; one to record shock, the other to record tilt. If either of these has been triggered, they will show a signal.

  • Page 18: Lifting And Positioning The Velox I Ultra Rapid Evc

    If after unpacking, the EVC is found to be damaged in any way, STOP immediately. Inform the OWNER of the EVC and TPS urgently, taking and sharing photographs to indicate the areas of this damage. See section 1.1 for TPS contact details. YOU will be informed of the next steps.
  • Page 19 Step 3: Fix the EVC directly to its concrete foundation using recommended fixings. You will find the details of these in Appendix C – Velox i Ultra Rapid EVC Reinforced Concrete Base, point 6. Step 4: Align the EVC, tightening all fixings to recommended torques.
  • Page 20 Step 7: Feed each LED’s power cable through to the inside of the EVC. The cable and plug from the LED are shown below on the left. They need to be connected to the socket which is part of the control harness inside the EVC which is shown on the right.

  • Page 21: Electrical Installation Of The Velox I Ultra Rapid Evc

    The information provided in this section is for guidance only. For the latest details on electrical installation please refer to ‘Unit Outline’, shown in Appendix A – Velox i Ultra Rapid EVC – Outline Drawing, which includes a link to the latest version.

  • Page 22: Termination Details

    4.5.2. Termination Details To make the internal electrical connections, the front cover of the Velox i Ultra Rapid EVC needs to be removed. THIS IS THE ONLY INSTANCE WHERE A COVER SHOULD BE REMOVED. Before doing this, it is important to ensure that any isolation devices inside the maintenance hatch are in the OFF position.

  • Page 23: Connection Of Ac Cables (Auxiliary Power)

    4.5.4. Connection of AC Cables (Auxiliary power) Figure 15 - 230 VAC Live (L), Neutral (N) and Earth (E) can take cable up to 2.5 mm² The 230 VAC 1P cables are terminated into standard ‘Wago’ push-in connectors. Cables should be terminated with an appropriately sized bootlace ferrule before being inserted.

  • Page 24: Safety Precautions During Installation, Operation And Maintenance

    Do not install the EVC close to any heat sources. • If in doubt refer to the installation drawing shown in Appendix A – Velox i Ultra Rapid EVC – Outline Drawing, with the link to the latest version, which will contain the latest information.

  • Page 25: Connection Of Communications (E.g. Ethernet)

    4.6.1. Connection of Communications (e.g. Ethernet) Figure 17 - The ethernet switch uses a standard RJ45 cables (spare ports are provided) Subject to specification, there may be a requirement for a communications cable such as Ethernet to be included. This should be routed through a gland and terminated with a suitable connector. When all cable connections have been made and verified, including the LED’s, the front cover can be refitted.

  • Page 26: Connection Of Cables To Hmi Screen, Payment Device And Pe Stud

    4.6.2. Connection of cables to HMI Screen, Payment device and PE stud When removing or refitting the front cover there is a need to remove the HMI, the Payment Device and the PE Stud, they must be reconnected, please see below images showing how to reconnect: Figure 18 - HMI Connections Figure 19 - Payment Device Connections CM1-1...
  • Page 27 Figure 20 - PE Connection Please note: The PE cable should be attached to the stud inside the front cover as shown. The fixings will be in place, remove the M8 nut, spring washer and flat washer, fit the cable then replace the nut and washers.

  • Page 28: Commissioning

    Please note: Commissioning can only take place once the installation stage has been completed correctly and in full. The commissioning of the Velox i Ultra Rapid EVC is a detailed and complex process which must only be undertaken by either Turbo Power Systems or an approved / trained person.

  • Page 29: Velox I Ultra Rapid Evc Operation

    Velox i Ultra Rapid EVC Operation The EVC’s HMI will take the USER through a step-by-step process of charging / discharging an EV. The sequence and screen layout may differ depending on the configuration of the EVC supplied. The basic sequence with example screen layouts are as follows:...
  • Page 30 If there is an issue, and the EVC is offline, the following screen will be shown. If this is the case, contact the Back Office or TPS Customer Support team for assistance. CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.

  • Page 31: Preventative Maintenance And Inspection Information

    Preventative Maintenance and Inspection Information PLEASE NOTE: the Velox i Ultra Rapid EVC contains no USER serviceable components. All repairs and maintenance can only be carried out by either Turbo Power Systems or an approved / trained representative. Please refer to customer contractual agreements for specific details.

  • Page 32: Cables, Connectors & Holsters

    7.1. Cables, Connectors & Holsters Locate the connectors at the sides of the Velox i Ultra Rapid EVC. Check that the cables are still located correctly within the glands through which they enter the EVC frame. Check all connectors for any damage.

  • Page 33: Air Ducts And Vents

    Locate the Maintenance Hatch on the LH frame leg. Remove the 4 off anti-tamper screws with a Security Torx T30 screwdriver. Inspect the cover gasket, replace if damaged (TPS part no. 409105). Refit the cover applying anti seize compound to the threads of the 4 screws.

  • Page 34: Hmi

    7.6. Locate HMI. Make sure it is clean and damage free. 7.7. Payment device / RFID Locate Payment device / RFID (if fitted). Make sure it is clean and damage free. Payment device / RFID 7.8. Isolation Switches Locate Isolation Switches Inside the Maintenance Hatch, see section 7.4 for details on hatch maintenance.

  • Page 35: Trouble Shooting

    Trouble shooting The table below shows a list of faults that may arise and actions that will help with troubleshooting. If they do not, please contact TPS for support. Refer to section 1.1 for details of how to do this. 8.1.

  • Page 36: End Of Life Disposal Of The Velox I Ultra Rapid Evc Or Component Parts

    End of Life Disposal of the Velox i Ultra Rapid EVC or component parts Incorrect waste handling has a negative impact on the environment and human health due to risk of exposure to hazardous substances. By following appropriate guidelines when dealing with disposal of the EVC or its components you will contribute to reuse and recycling of materials and protection of the environment.

  • Page 37: Appendix A - Velox I Ultra Rapid Evc - Outline Drawing

    Appendix A – Velox i Ultra Rapid EVC – Outline Drawing Indicative information only. Dimensions may be subject to change. Latest revision can be found here: 801325-Outline CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.

  • Page 38: Appendix B - Velox I Ultra Rapid Evc - Foundation Proposal

    Appendix B – Velox i Ultra Rapid EVC – Foundation Proposal Indicative information only. Dimensions may be subject to change. Latest information can be found on the manufacturer’s website, link below: https://nal.ltd.uk/ev-charging/products/universal-ev-foundation/high-power-foundation CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.

  • Page 39: Appendix C - Velox I Ultra Rapid Evc Reinforced Concrete Base

    Appendix C – Velox i Ultra Rapid EVC Reinforced Concrete Base CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.
  • Page 40 CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.

  • Page 41: Appendix D - Installation Checklist Document

    Have you unpacked the Velox i Ultra Rapid EVC as set out in section 4.3? Have you lifted the Velox i Ultra Rapid EVC in location as set out in section 4.4? Have you mechanically installed the Velox i Ultra Rapid EVC as set out in section 4.2? Have you electrically installed the Velox i Ultra Rapid EVC as set out in section 4.5?

  • Page 42: Appendix E - Maintenance & Inspection Record

    - Description Cables, Connectors & All operating correctly Holsters Cleaning the Exterior of Clean and Functional the Velox i Ultra Rapid EVC Air Ducts All operating correctly Enclosure and Hatches All operating correctly LEDs All operating correctly All operating correctly...

  • Page 43: Appendix F - Packing

    Appendix F – Packing Link to the latest version:- 801325 120kW 920V EV Charger Packing Instruction CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.
  • Page 44 This page is intentionally left blank. CM1-1 Revision 1 The information contained in this document is to be considered proprietary information. It shall not be reproduced, disclosed, or used without the prior written permission of Turbo Power Systems Ltd.

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