Lincoln Electric VELION DC Fast Charger K5490-1 Installation And Commissioning Manual
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Lincoln Electric VELION DC Fast Charger K5490-1 Installation And Commissioning Manual

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Installation and Commissioning Manual
VELION™ DC Fast Charger
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www.lincolnelectric.com/register
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www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10701
| Issue Date May - 24
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Model Numbers:
K5490-1
Need Help? Call 1.216.481.8100
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric VELION DC Fast Charger K5490-1

  • Page 1 Installation and Commissioning Manual VELION™ DC Fast Charger For use with machines having Model Numbers: K5490-1 Need Help? Call 1.216.481.8100 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents Table of Contents ............................III List of Figures ..............................V List of Tables ............................... VII Revision History ............................VIII Document Description ........................... 1 Introduction to the Manual..........................2 Symbols ..............................2 Abbreviations ............................. 3 Terminology ...............................

  • Page 3: Table Of Contents

    Table of Contents Preparing the Cabinet for Installation ...................... 25 Attaching the Cabinet to the Anchors...................... 26 Wiring the Charger Tower ........................... 27 Connecting Power ........................... 28 Installing the Earth Ground ........................28 Connecting AC Power ..........................29 Connecting DC Power ..........................30 Connecting Signal Wiring ........................

  • Page 4: List Of Figures

    List of Figures List of Figures Figure 1 Pedestal Exterior Components ..................... 16 Figure 2 Pedestal Cable Management ....................... 16 Figure 3 Pedestal Floor Space Requirements .................... 17 Figure 4 Charger Tower Exterior Components ................... 17 Figure 5 Charger Tower Interior Component Locations ................18 Figure 6 Charger Tower Cabinet Space Requirements ................
  • Page 5 List of Figures THIS PAGE INTENTIONALLY LEFT BLANK Page VI VELION™ DC Fast Charger...

  • Page 6: List Of Tables

    List of Tables List of Tables Table 1 Symbols ............................2 Table 2 Abbreviations ........................... 3 Table 3 Terminology ............................. 4 Table 4 VELION™ Charger Tower Specifications ..................12 Table 5 VELION™ Pedestal Specifications ....................13 Table 6 System Certification Standards ...................... 13 Table 7 Pedestal Dimensions ........................

  • Page 7: Revision History

    Third Draft containing comments from Bryan and Steve. Added partial updated graphics and comments from Daimler Truck North America - Remote 1/18/24 Desktop Review - R2400103. And Teal, Lincoln Electric and, Altaworx Logistics Email 1/17/24 commissioning form. 2/07/24 Added adapter plate change. Updated Preventive Maintenance section and changed text box formatting in figures for html translation.

  • Page 8: Document Description

    Document Description Document Description Document Description Symbols.............................. 2 Abbreviations ............................. 3 Terminology ............................4 Security and Data Storage ......................... 4 Accessing Data ..........................4 VELION™ DC Fast Charger Page 1...

  • Page 9: Introduction To The Manual

    Document Description Document Description Introduction to the Manual The original instructions of this document are in English (EN-US). All other language versions are translations of the original instructions. It is not always possible to show the configuration of your EVSE (electric vehicle supply equipment).

  • Page 10: Abbreviations

    Document Description Document Description Symbol Description Signal Word lockout and tagout procedures to reduce the chance of injury or death. Recycle electronics equipment. Follow local disposal WARNING Proper procedures. Electronics Disposal AC Current Symbol 3 Phase Alternating Current Supply Symbol 3 Phase Supply Abbreviations The following list contains the abbreviations used in this document.

  • Page 11: Terminology

    Document Description Document Description Terminology The following list contains the terms used in this document. Table 3 Terminology Term Definition Network operating Facility of the manufacturer to do a remote check on the correct operation of center the charger. Cabinet Enclosure of the charger, including the components on the inside.

  • Page 12: Important Safety Instructions

    Important Safety Instructions Safety Important Safety Instructions Owner Responsibilities ........................6 Liability ............................... 6 Cyber Security ............................ 6 Personal Protective Equipment ......................7 Electronics Disposal ........................... 7 Fire Safety ............................7 Emergency Power Shut-Off ....................... 7 Electric and Magnetic Fields (EMF) ....................7 Qualifications for Installers .........................

  • Page 13: Owner Responsibilities

    Only make changes to the charger if the manufacturer approves of the changes in writing.  Do not use a charging plug not approved by The Lincoln Electric Company to charge an EV.  Do not charge an EV battery not approved by the vehicle manufacturer.

  • Page 14: Personal Protective Equipment

    Important Safety Instructions Safety The manufacturer and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information. Personal Protective Equipment Personal protective equipment (PPE) is required for all persons on-site during the preparation, construction, installation, maintenance, repair or removal of the charging equipment or related materials and equipment used for site preparation, installation, setup, or maintenance of the EV (electric vehicle) charger.

  • Page 15: Qualifications For Installers

    Safety Important Safety Instructions before using the Velion DC Fast Charger. Consult with your doctor before powering up or operating the charger. These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and reflection from structures, objects, and people. Exposure to EMF fields may have other health effects which are now not known.
  • Page 16 Important Safety Instructions Safety  Install equipment in accordance with the U.S. National Electrical Code, all local codes, and the manufacturer’s recommendations.  Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. DANGER Arc Flash Hazard An arc flash can cause serious injury or death.
  • Page 17 Discarding Electrical Components WARNING General Risk Lincoln Electric requires the return of non-operational charger tower cabinet and pedestal modules. Contact Lincoln Electric for more information. Dispose of miscellaneous electrical components safely. Incorrect waste handling can negatively affect the environment and human health due to potentially hazardous substances used in the components.

  • Page 18: Velion™ Ev Charger Specifications

    Specifications Specifications VELION™ EV Charger Specifications Specifications ............................. 12 VELION™ DC Fast Charger Page 11...

  • Page 19: Specifications

    Specifications Specifications Specifications Table 4 VELION™ Charger Tower Specifications Charger Tower Specifications Charging Type DCFC, DC Fast Charging 200A Maximum Input Current Input Voltage 460VAC +/- 10% (60Hz), 3-Phase, Protective Earth (UL Model) DC Output Voltage 200-1000V DC Output Current Up to 300A DC Output Power (max) 150kW...

  • Page 20: Table 5 Velion™ Pedestal Specifications

    Specifications Specifications Table 5 VELION™ Pedestal Specifications Pedestal Specifications Outlet Type Single CCS Cable Network Connection GSM/3G/4G modem;10/100 Base-T Ethernet Communication OCPP 2.0.1 and 1.6 Authentication/Payment RFID/Credit card reader/App User Interface 15 in LCD high-contrast touchscreen Environmental Rating NEAM TYPE 3R (IP-54 equivalent) IK Rating IK08 -30 deg C to +50** deg C...
  • Page 21 Specifications Specifications THIS PAGE INTENTIONALLY LEFT BLANK Page 14 VELION™ DC Fast Charger...

  • Page 22: System Overview

    System Overview System Overview Pedestal Overview .......................... 16 Exterior Components ......................... 16 Interior Components ........................17 Space Requirements ......................... 17 Charger Tower Overview ........................ 17 Exterior Components ......................... 17 Interior Components ........................18 Space Requirements ......................... 18 VELION™ DC Fast Charger Page 15...

  • Page 23: Pedestal Overview

    General Description System Overview This section describes the pedestal and charger tower components, their placement, and orientation. Pedestal Overview Exterior Components Figure 1 shows the placement and function of the pedestal exterior components. Number Description Function RFID Charge Card Reader User card reader for billing Operator Input Pushbuttons Manual pushbuttons for operator commands...

  • Page 24: Interior Components

    System Overview Interior Components The pedestal has no user, troubleshooting, or service components inside the operator interface. Refer to the Installing the Pedestal Section for the layout of the pedestal wiring components. Pedestal Dimensions Dimensions of the pedestal are 24 x 19 x 87 inches (610 x 483 x 2210 mm). Table 7 Pedestal Dimensions Number Dimension...

  • Page 25: Interior Components

    General Description System Overview Interior Components Figure 5 shows the names and layout of the components in the charger tower cabinet. Number Part Power Modules (4 per tower) Front Door and Back Door Power Interlock Switches Power Module Cooling Fans (2 per module) AC Input Connections DC Output Connections...

  • Page 26: Figure 6 Charger Tower Cabinet Space Requirements

    System Overview Figure 6 Charger Tower Cabinet Space Requirements Door Path Cabinet Dimension Number Dimension Number Dimension 17 in (432 mm) 29.56 in (751 mm) 23.7 in (602 mm) 2.44 in ( mm) 15.8 in (402 mm) 1.65 in (62 mm) 17 in (432 mm) 21.12 in (537 mm) 23.7 in (602 mm)
  • Page 27 General Description System Overview THIS PAGE INTENTIONALLY LEFT BLANK Page 20 VELION™ DC Fast Charger...

  • Page 28: Receiving The Charger

    Unpacking should be done by an experienced, qualified installation engineer.  Inspecting the shipment includes comparing shipping lists to the delivered shipment.  Check the condition of the shipment by inspecting the containers.  Report damage and missing components to Lincoln Electric. VELION™ DC Fast Charger Page 21...

  • Page 29: Moving Shipping Containers

    Safety Messages Receiving the Charger Moving Shipping Containers Refer to the Specifications Section for weight of the containers. Moving containers shall be supervised by a structural engineer licensed in the local governing jurisdiction. Number Part Pedestal Charger Tower Cabinet Figure 8 Moving Shipping Containers Pedestal Charger Tower Number...

  • Page 30: Installing The Charger Tower

    ling the Charger Tower Installing the Charger Tower Installing the Charger Tower Safety ............................23 Attaching the Charger Tower to the Foundation ................24 Required Tools Not Supplied ....................24 Preliminary Requirements ......................24 Preparing the Cabinet for Installation .................... 25 Attaching the Cabinet to the Anchors....................

  • Page 31: Attaching The Charger Tower To The Foundation

    Installing the Charger Tower Installing the Charger Tower Attaching the Charger Tower to the Foundation This section describes the charger tower installation to the completed foundation. Physical installation requires power wiring, conduit, and foundation placement before the charging system can be set into place and wired.

  • Page 32: Preparing The Cabinet For Installation

    ling the Charger Tower Installing the Charger Tower Wiring Conduit The wiring and conduit shall be installed per the local jurisdiction installation codes. Provided it does not conflict with jurisdictional codes. It is preferred to route the wiring in the conduit as shown in Figure 10. Cut the conduit extension a minimum of 2 inches (50 mm) above the foundation.

  • Page 33: Attaching The Cabinet To The Anchors

    Installing the Charger Tower Installing the Charger Tower Number Function Cabinet Floor Washer Lock Washer Securing Nut Structural Anchor Template Foundation Figure 12 Charger Power Cabinet Installation Attaching the Cabinet to the Anchors 1. Lift the cabinet by the 4 lift eyebolts only (1). 2.

  • Page 34: Wiring The Charger Tower

    Wiring the Charger Tower Wiring the Charger Tower Connecting Power ........................... 28 Installing the Earth Ground ......................28 Connecting AC Power........................29 Connecting DC Power ........................30 Connecting Signal Wiring ....................... 30 DANGER Risk of Electric Shock Electricity can cause injury or death. Document and follow lockout and tagout procedures when working with live circuits to reduce the chance of injury or death.

  • Page 35: Connecting Power

    ring the Charger Tower Wiring the Charger Tower Connecting Power Connecting power includes connecting the ground and source power lines to the charger tower and DC power with the communication wires to the pedestal. The earth ground and power wiring shall be approved by an electrical engineer licensed in the local governing jurisdiction.

  • Page 36: Connecting Ac Power

    Wiring the Charger Tower Wiring the Charger Tower Connecting AC Power Preliminary Requirements  Verify and document the input power has been locked/tagged out.  Size the AC wires for the application.  Cut the wires to length. Strip wire 15/16". ...

  • Page 37: Connecting Dc Power

    ring the Charger Tower Wiring the Charger Tower Connecting DC Power Preliminary Requirements 1. Verify and document the input power has been locked/tagged out. 2. Size the DC voltage wire for the application. 3. Prepare the wire for a lug to attach onto the 3/8 in.

  • Page 38: Figure 18 Charger Tower Cabinet Communication Wiring

    Wiring the Charger Tower Wiring the Charger Tower Procedure 1. Plug in the connector for the communications wires and the connector for the door open switch to the connectors. 2. Attach the communication wires to the terminal block. Torque the terminal 6-8 in.
  • Page 39 ring the Charger Tower Wiring the Charger Tower THIS PAGE INTENTIONALLY LEFT BLANK Page 32 VELION™ DC Fast Charger...

  • Page 40: Installing The Pedestal

    Installing the Pedestal Installing the Pedestal Installing the Pedestal Bracket and Base to the Foundation ............34 Pedestal, Adapter Bracket with Base and Mounting Hardware............. 34 Installing the Adapter Bracket and Base to the Foundation Procedure ........35 Installing the connections from Charge Tower Procedure ............35 Installing the Pedestal to the Foundation ..................

  • Page 41: Installing The Pedestal Bracket And Base To The Foundation

    Installing the Pedestal Installing the Pedestal Bracket and Base to the Foundation This section shows the steps for installing the pedestal to the foundation. Pedestal, Adapter Bracket with Base and Mounting Hardware Number Function Leveling Nuts Structural Anchors Adapter Bracket and Base (Inside Pedestal) Wiring Access Cover Foundation...

  • Page 42: Figure 22 Start Point For Leveling The Pedestal

    Installing the Pedestal Required Tools Not Supplied T27 Security Torx bit driver for the ¼-20.   Mounting hardware for the pedestal.  Construction level.  Hoist cables or certified lift straps. Miscellaneous Hand tools.  Installing the Adapter Bracket and Base to the Foundation Procedure 1.

  • Page 43: Installing The Pedestal To The Foundation

    Installing the Pedestal Number Description 48V + 48V - CAN HI CAN Low Shield Ground Unused Unused Unused Unused Figure 22 Connecting the Communication Lines from Charge Tower Installing the Pedestal to the Foundation WARNING Risk of Pinching or Crushing ...
  • Page 44 Installing the Pedestal Number Description 48V + 48V - CAN Low CAN HI Shield Ground Unused Unused Figure 24 Connecting the Unused Communication Lines from Pedestal Unused VELION™ DC Fast Charger Page 37...
  • Page 45 Installing the Pedestal THIS PAGE INTENTIONALLY LEFT BLANK Page 38 VELION™ DC Fast Charger...

  • Page 46: Commissioning The Charger

    Commissioning the Charger Charger Commissioning Commissioning the Charger Charger Commissioning ......................... 40 Commissioning Procedure ......................40 Page 39 VELION™ DC Fast Charger...

  • Page 47: Charger Commissioning

    Charger Commissioning Commissioning the Charger Charger Commissioning Only a charge-point operator (CPO), site operator, or owner is qualified to register and commission the charger. 1. Tell the owner that the charger is ready for commissioning. 2. Make sure that the following data is available. ...

  • Page 48: Confirming Power

    Commissioning the Charger Charger Commissioning Scan the QR Code getamop URL Scanning the QR Code populates the form and turns on the SIM card. QR Code Company Name Customer Name Customer Contact # Billing Contact Name Billing Contact # Billing Email Address Service Address Charging Station Serial # Rate Plan Choice...

  • Page 49: Measuring Ac Voltage

    Charger Commissioning Commissioning the Charger An AMOP representative will contact you to establish your billing account within 48 business hours. If you need immediate assistance, please contact us directly at activations@amop.services or call (877)-926- 2589. We look forward to serving you! AMOP Client Success Team Note: The end client will need to provide a signed agreement along with payment information through DocuSign.
  • Page 50 Commissioning the Charger Charger Commissioning Fill in the Commissioning and Registration Form Continued Page 43 VELION™ DC Fast Charger...

  • Page 51: Figure 27 Commissioning The Charger

    Charger Commissioning Commissioning the Charger Figure 27 Commissioning the Charger Page 44 VELION™ DC Fast Charger...

  • Page 52: Using The Charger

    Using the Charger Charger Commissioning Using the Charger Charger User Interface ........................46 Power Outages .......................... 46 Starting a Charge Session ......................46 Stopping a Charge Session ....................... 47 Charging Display Screens ......................47 Description of the Pedestal Buttons ................... 47 Caution General Risk Make sure that you have approval of the manufacturer to use the charger after...

  • Page 53: Charger User Interface

    Charger Commissioning Using the Charger Charger User Interface Indicator Description Out of Order Charging Available/Idle Figure 28 Charger Operation Indicator Light Number Part Payment Terminal Vehicle Charge Cable and Holder Touchscreen Manual Pushbuttons Figure 29 Charger User Interface Power Outages If there is a power outage while charging a vehicle, charging automatically resumes within 1 to 3 minutes after power restoration.

  • Page 54: Stopping A Charge Session

    Using the Charger Charger Commissioning Stopping a Charge Session 1. On the touchscreen, press the Stop button. When the battery is full, the charge session stops automatically. 2. If the touchscreen shows a message to authorize the charge session, do the instruction that the touchscreen shows.
  • Page 55 Charger Commissioning Using the Charger THIS PAGE INTENTIONALLY LEFT BLANK Page 48 VELION™ DC Fast Charger...

  • Page 56: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance Recommended Preventive Maintenance ..................54 Cleaning the Pedestal ........................ 54 Inspecting the Pedestal Cable Connector Latch................ 55 Replacing the Cabinet Air Filters ....................55 Replacing the Cabinet Front or Back Door Upper Filter ............56 Replacing the Cabinet Back Door Lower Filter ................56 Replacing the Cabinet Front Door Lower Filter .................

  • Page 57: Recommended Preventive Maintenance

    Contact Lincoln Electric to report equipment concerns. Email: Velion service@lincoln.com or call EV Charger Support at Lincoln Electric at phone number (888-935-3877).  Inspect the charger plug handle latch for effective operation. The latch must lock the charger handle to the vehicle connector.

  • Page 58: Inspecting The Pedestal Cable Connector Latch

    Preventive Maintenance Table 9 Preventive Maintenance Schedule Frequency Task Related Information https://www.lincolnelectric.com/en/ 6 Months Replace the charger tower cabinet filters. Service-Navigator Replace more often in dirty environments. 6 Months 1. Inspect the entire charger tower cabinet Schedule service or replacement with and pedestal for damage.

  • Page 59: Replacing The Cabinet Front Or Back Door Filter

    Preventive Maintenance WARNING Personal Injury Hazard  Dispose of filters and consumable products according to local waste and recycling regulations.  If safety devices are removed, immediately install the safety devices before power is applied.  Personal protective equipment required by local codes including safety shoes, hard hat, safety glasses, and gloves are worn.

  • Page 60: Replacing The Pedestal User Interface Seals

    Preventive Maintenance Replacing the Pedestal User Interface Seals 1. Remove the 6 Torx screws attaching the operator interface panel bezel. 2. Remove the operator interface panel bezel 3. Remove the 4 Torx screws sealing the operator interface panel. 4. Completely remove the old seal and all old adhesive residue. 5.
  • Page 61 THIS PAGE INTENTIONALLY LEFT BLANK Page 54 VELION™ DC Fast Charger...
  • Page 62 IM10701 Issue Date 05/24 THE LINCOLN ELECTRIC COMPANY 22801 St. Clair Avenue ● Cleveland, OH ● 44117-1199 ● U.S.A. © Lincoln Global, Inc. All Rights Reserved. Phone: +1.216.481.8100...

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