Smappee EV Ultra Installation Manual
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Smappee EV Ultra Installation Manual

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Smappee EV Ultra
Installation manual
English – Version 1.5 – March 2023

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  • Page 1 Smappee EV Ultra Installation manual English – Version 1.5 – March 2023...
  • Page 2 The specifications and other information in this document were verified to be accurate and complete at the time of its publication. Due to ongoing product improvement, this information is subject to change at any time without prior notice. For the latest information, see our online documentation: https://www.smappee.com/downloads...

  • Page 3: Table Of Contents

    5. Technical specifications................... 9 6. Preparing the installation ................13 7. Installation and activation ................15 8. Maintenance ....................37 9. Using the EV Ultra ..................38 10. Declaration of conformity ................43 Smappee EV Ultra – Installation manual – English...

  • Page 4: Introduction

    DC charging station for businesses. This installation and user manual tells you how to install and use the Smappee EV Ultra. We advise you to read the contents of this manual carefully, to ensure a safe and proper installation and enable you to use all the advanced features of this product to the full.

  • Page 5: Safety Instructions

    Safety warning Fully read and follow the safety instructions below before you install, service or use your Smappee EV Ultra. The installer must ensure that the charging station is installed in accordance with the relevant national and local regulations. Carrying out activities on this charging station without the relevant knowledge and qualifications can lead to serious accidents and death.

  • Page 6: Models

    3. Models Article no. Description EVBU-80-CCS3R 5425036933873 Smappee EV Ultra 80S EVBU-200-CCS3R 5425036933767 Smappee EV Ultra 200S Smappee EV Ultra – Installation manual – English...

  • Page 7: Components

    5x Inverter • 1x Mounting anchor Article codes Article no. Description EVBU-CNV40-1 5425036933774 EV Ultra Inverter 40 kW EVBU-ANCHOR 5425036933828 EV Ultra Mounting anchor EVBU-CBL-CSS250-3 5425036933842 EV Ultra Charging Cable CCS 250A 3.25m Smappee EV Ultra – Installation manual – English...
  • Page 8 3. Manufacturing date 4. Degree of protection 5. Rating 6. Maximum DC output current 7. Maximum DC output voltage 8. Operating temperature 9. QR code containing article number and serial number 10. Serial number Smappee EV Ultra – Installation manual – English...

  • Page 9: Technical Specifications

    OCPP 1.6 JSON, ready for update to OCPP 2.0 Metering kWh meter compliant with IEC 62053-21 Certifications and Standards Product certification Standards IEC 61851, ISO 15118 Environment Enclosure material Magnelis Enclosure standard colours RAL9016 (star white) + RAL7021 (black grey) Smappee EV Ultra – Installation manual – English...
  • Page 10 20 kg Charging cable 9 kg 9 kg Anchor 20 kg 20 kg Charging cable length 3.25 m Stationary / moveable Fixed installation External design Enclosed assembly Mounting method Floor / Ground-mounted Smappee EV Ultra – Installation manual – English...
  • Page 11 Performance graphs The following graph shows the DC output power for both the 80kW and 200kW EV Ultra, related to the AC input line voltage.
  • Page 12 Smappee EV Ultra – Installation manual – English...

  • Page 13: Preparing The Installation

    6. Preparing the installation First step is to prepare the physical installation of the EV Ultra as described in this chapter. Installation prerequisites • Calculate the existing electrical load to find the maximum operating current for the charging station installation. Note that with the Smappee Overload functionality more charging stations or the total maximum operating current can be higher than the physical installation allows.
  • Page 14 Needle-nose pliers. Cable lugs M10 with a maximum width of 35 mm 17 mm socket wrench with ratchet handle Supplies (not included) Ethernet cable and RJ45 connector for wired communication. Power supply cables Smappee EV Ultra – Installation manual – English...

  • Page 15: Installation And Activation

    7. Installation and activation This procedure describes the required steps for the physical installation of the EV Ultra. CAUTION: The installation must be carried out by a qualified professional who has read this manual and works in compliance with IEC 60364 standards. Neglecting this may lead to severe injuries or hazardous situations while working with electricity.
  • Page 16 Unboxing the different components doesn’t need special attention. Just keep in mind to store the cardboard, as this can be used to safely store the front and back panel while installing the EV Ultra. Assemble the EV Ultra anchor The Smappee EV Ultra is designed to be installed at ground level using the supplied anchor.
  • Page 17 Place and secure the cover plate on the top using the supplied nuts and a socket wrench. Tighten the 4 mounting corners at the bottom of the assembling using a socket wrench. Smappee EV Ultra – Installation manual – English...
  • Page 18 This allows the EV Ultra to be integrated in the surrounding soil. When mounting the EV Ultra anchor, there is no left or right side of the anchor. Only the top and bottom needs to be considered, where the dummy plate of the EV Ultra is the top. In other words: the anchor can be turned 180°...
  • Page 19 The EV Ultra can be placed maximum 3 cm below the top of the surrounding soil for aesthetic purposes. It cannot be placed lower as there will be risk of water ingress. To correctly install the EV Ultra anchor: a. Create a foundation made of a dry mixture of sand and cement. The minimum dimensions of this foundation are 450 mm by 750 mm.
  • Page 20 Place the EV Ultra on the anchor a. While the EV Ultra is in the cardboard box, first remove the backplate of the EV Ultra. The back plate is the one without the Smappee avatar. This removes some weight from the charger and provides extra grip.
  • Page 21 Remove the front plate of the EV Ultra by unscrewing the upper 4 screws (using a 5 mm hex screwdriver). After unscrewing the 4 screws, the front plate can be removed by lifting and moving it forward.
  • Page 22 Leave the top plate mounted to the charging station as is. e. Place the EV Ultra (with plate) over the anchor. Make sure all holes align with sides of the anchor and the power supply and ethernet cables go through the central opening of the EV Ultra.
  • Page 23 Use the supplied nuts to secure the EV Ultra to the anchor. Tighten the nuts using a socket wrench. Smappee EV Ultra – Installation manual – English...
  • Page 24 Protect the power supply cables using the plastic cover of the load break switch. Connect the ground (PE) to the distribution block on the right of the EV Ultra, using an 8 mm hex wrench. Tighten it to 25 Nm.
  • Page 25 Auxiliary power supply For the internal electronics of the EV Ultra, an extra 5G2.5 mm² cable is needed. This 5G2.5 mm² cable is connected to the internal 20 A fuses and connector available at the bottom right corner. Phases 1, 2, 3 and neutral are directly connected to the fuses, while the ground is connected to the connector just right of the fuses.
  • Page 26 4 conductors are needed for this type of installations: 3 phases and 1 (PEN) ground cable. The internal wiring of the EV Ultra assumes a TN-C grid by default. Reason why a connection is made between the neutral and ground connection.
  • Page 27 Connect the ground to the distribution block on the right of the EV Ultra, using an 8 mm hex wrench. Tighten it to 25 Nm. TN-S grid In a TN-S grid, the PE and N are separate conductors that are connected together only near the power source.
  • Page 28 The picture below shows the situation after removing the pre-wired cables: Mount the 5G2.5 mm² cable to the connecting block, respecting the colour assignment. The 5G2.5 mm² cable is secured with a 20A circuit breaker in the distribution panel. Smappee EV Ultra – Installation manual – English...
  • Page 29 RFID reader. To do this, use a 2.5 mm hex wrench. The inverters in the back have the DC output at the bottom of each slot, while the inverters in the front have the DC output at the top. Smappee EV Ultra – Installation manual – English...
  • Page 30 Mount the inverters for Ultra 80S The EV Ultra 80S is supplied with three inverters. As the EV Ultra 80S has the same housing as the EV Ultra 200S, it is important to only use the slots reserved for the EV Ultra 80S.
  • Page 31 Mount the inverters for Ultra 200S The EV Ultra 200S is supplied with five inverters. Each inverter slides into a foreseen slot. There are four slots in the back and one in the front. There is no specific order to be respected when mounting the inverters into the slots.
  • Page 32 25 Nm. The remaining six control cables have a label from 1 to 6. Mount each cable to the corresponding connector within the EV Ultra. Use a small screwdriver to connect the cable. Determine CCS2 Socket tightness The tightness of the CCS2 socket in the cable holder can be determined by adjusting two set screws within the housing of the EV Ultra.
  • Page 33 Internet connectivity An Ethernet cable should be used to provide network connectivity for the EV Ultra. This Ethernet cable is mounted in the open RJ-45 LAN port of the Teltonika router. Smappee EV Ultra – Installation manual – English...
  • Page 34 Internet connection. Switch on the EV Ultra Before switching on the EV Ultra, make sure no tools are near any power supply connections and people stand free of the EV Ultra. After switching on the EV Ultra, wait for approximately 30 seconds to verify the following LED indicators: •...
  • Page 35 Activation This procedure is done with the Smappee mobile app. You can download this from the Apple App Store for iOS or the Google Play store for Android phones. The Smappee App will guide you through the various steps to fill in all the required information.
  • Page 36 Use four screws to fix the top of the front plate, using a 5mm hex wrench. Front and back plate should align. e. To end, use 8 screws to fix the front and back plate to the floorplate of the anchor. Smappee EV Ultra – Installation manual – English...

  • Page 37: Maintenance

    8. Maintenance For safe and regular operation of the EV Ultra, regular maintenance or control is required. Refer to the table below for the intended maintenance work and interval. All points in the table are considered mandatory and must be carried out by a certified technician.

  • Page 38: Using The Ev Ultra

    1. Plug and charge: Simply insert the connector in the EV and start charging. 2. Swipe and charge: Insert the connector, swipe your RFID card and start charging. 3. Scan and charge: Insert the connector, scan the QR code in the Smappee App and start charging.
  • Page 39 Swipe and charge Charging sessions can be started using an RFID card. You can either use a Smappee Smart Charge Card for free charging or (if activated) a third party eMSP card to pay for charging sessions. The RFID readers are situated at the side of the EV Ultra, close to the connector.
  • Page 40 Scan and charge The user pays by credit card (Visa or Mastercard) using the Smappee App. They scan the QR code shown on the charging station and the app will guide them through the process of starting the charging session. It is also possible to set discount rates for specific users Scan and charge is activated using the Smappee dashboard.
  • Page 41 The Smappee EV Ultra is Check the manual or contact unavailable. your supplier for more info and further steps. Red flashing Your charge card is not Contact your charge card authorised. supplier. Smappee EV Ultra – Installation manual – English...
  • Page 42 Check charging module communication, check The difference between the communication cable connection; If the module current and average communication is good and alarm persists, replace current is too large charging module. Smappee EV Ultra – Installation manual – English...

  • Page 43: Declaration Of Conformity

    DC Charging equipment : IEC 61851-1 (2017), IEC 61851-21-2 (2018), IEC 61851-23 (2014), IEC 61851-24 (2014) , ISO 15118 / EN61558-1 * Other applicable standards and certifications: IEC 60364, IEC 62192-1, IEC 62192-2 Authorized signatory Stefan Grosjean Smappee EV Ultra – Installation manual – English...

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