ABB HVC 200 Operation And Installation Manual Download Page 30

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When it is activated, the emergency stop button (EMO) trips the breakers to cut off

the power to the chargers.

Note:
•

The emergency stop button (EMO) is optional and the placement of

this button is customized for every configuration.

•

For the connection information, refer to section

6.3.15

Description

HVC 200/300/360-EN | 002

Summary of Contents for HVC 200

Page 3: ...14 2 3 Responsibilities for the owner 15 2 4 Required qualifications for the qualified installation engineer 15 2 5 Personal protective equipment 16 2 6 Safety instructions during transport 16 2 7 Saf...

Page 4: ...epare the foundation 36 5 4 1 Prepare a foundation general procedure 36 5 4 2 Prepare the foundation for the power cabinet concrete 37 5 4 3 Prepare a metal foundation for the power cabinet 37 5 4 4 I...

Page 5: ...has a ferrule 57 6 4 Precommissioning mode 57 6 4 1 General information 57 6 4 2 Precommissioning mode general procedure 58 6 4 3 Do an inspection of the PE connection 59 6 4 4 Connect the 120 V cabl...

Page 6: ...ifications 76 12 6 Cleaning specifications 76 12 7 Dimensions and mass 77 12 8 Cable slack 78 12 9 Space requirements 79 12 10 Foundation specifications 80 12 10 1 Power cabinet custom foundation 80 1...

Page 7: ...guration 87 12 14 3 360 kW configuration 87 12 15 DC output specifications 88 12 15 1 DC output specifications 88 12 15 2 Power curve 89 12 16 Protection for the AC auxiliary 90 12 17 Power consumptio...

Page 8: ...responsibilities of the owner refer to section 2 3 For the required qualifications for the installation engineer refer to section 2 4 1 3 Revision history Version Date Description 001 October 2023 In...

Page 9: ...the document in a safe location that you can easily access This document is a part of the EVSE 1 9 General symbols and signal words Signal word Description Symbol Danger If you do not obey the instruc...

Page 10: ...s required according to the local rules Alternating current supply Note It is possible that not all symbols or signal words are present in this document 1 10 Special symbols for warnings and dangers S...

Page 11: ...he EVSE You can find the contact data here https new abb com ev charging 1 12 Abbreviations Abbreviation Definition AC Alternating current BESS Battery energy storage system CAN Controller area networ...

Page 12: ...ponsible for the transmission and distribution of electricity Applicable laws and local rules All rules that apply to the EVSE during the entire lifecycle of the EVSE This includes national laws regul...

Page 13: ...ont side face forward to the EVSE during normal use B Left side C Right side D Rear side X X direction positive is to the right Y Y direction positive is to the front Z Z direction positive is upward...

Page 14: ...fessional or incorrect installation installation not complying to standards or installation not following the installation instructions contained in the product specific manual Improper operation in b...

Page 15: ...ployees and third parties are qualified according to the applicable laws and local rules to do the work To make sure that there is sufficient space around the EVSE to safely do maintenance and install...

Page 16: ...y Take into account the mass and the center of gravity of the EVSE Refer to section 12 7 Obey the applicable safety instructions for the hoisting equipment or for the forklift truck For example the in...

Page 17: ...safety devices after the work is completed Put on the correct personal protective equipment Refer to section 2 5 2 8 Safety instructions for use Do not use the EVSE and immediately get in contact wit...

Page 18: ...zardous voltage that gives risk of electrocution Risk of pinching or crushing of body parts Rotating parts that can cause a risk of entrapment Hot surface that gives risk of burn injuries Appliance cl...

Page 19: ...manufacturer ABB E mobility Inc 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 dat...

Page 20: ...D Global identification number of the EVSE E Serial number F Mass of the EVSE G EVSE rating H Address of the manufacturer I UL mark J QR code with the global identification number of the EVSE K QR cod...

Page 21: ...with accessories that the manufacturer provides and that obey the local rules 3 3 Overview 3 3 1 System overview A B C1 C2 C3 C4 The power cabinet has variants with 2 or 4 outlets Element Description...

Page 22: ...n the inside of the EVSE LED indicators To indicate the status of the EVSE outlets Door To give authorized personnel access to the inside of the cabinet Type plate To show the identification data of t...

Page 23: ...onnect the AC power AC input fuses To protect the device from a power disruption PE busbar To connect PE cables AC plate To connect the AC and the precommissioning ca bles Cable inlet Opening for the...

Page 24: ...ommissioning cables Terminal X2 To connect the AC cables Terminal X3 To connect the AC cables Fuse F10 To prevent the electrical circuit from an overload Fuse F21 To prevent the electrical circuit fro...

Page 25: ...iber converters to connect the optical fiber cables Terminals D6 D9 Ethernet to fiber converters to connect the optical fiber cables Terminal X10 To connect the LED cables Terminal X9 To connect the R...

Page 26: ...C B A F E G H I H H I H A PE B L1 cables C L2 cables D L3 cables E Cables for terminals X1 X2 X3 F Cables for terminals X4 X10 terminals X84 X87 terminals D1 D4 and terminals D6 D9 G DC out H DC out I...

Page 27: ...outlet 2 C LED indicator for outlet 3 D LED indicator for outlet 4 The LED indicators show the status of the EVSE Table 1 Indications of the lights LED color LED status Status of the EVSE Idle Ready t...

Page 28: ...at the outlets Section 3 5 2 3 5 1 Static allocation 50 50 25 25 25 25 1 2 3 4 1 2 If there are two outlets each EV receives 50 percent of the available power of the EVSE If there are four outlets ea...

Page 29: ...ets is percent of the available power Example of an EVSE with four outlets EV1 receives 100 percent of the power from the EVSE until it is fully charged EV2 EV 3 and EV 4 must wait until EV1 is fully...

Page 30: ...e breakers to cut off the power to the chargers Note The emergency stop button EMO is optional and the placement of this button is customized for every configuration For the connection information ref...

Page 31: ...equipment PPE and follow all the applicable Health and Safety measures applicable to the working area Check the position of the center of gravity before lifting the power cabinet the higher the positi...

Page 32: ...r chain A of the hoisting equipment to the eye bolts B 2 Move the cabinet to the correct location 4 1 2 Move the packaged cabinet with a forklift truck Preliminary requirements The cabinet is packed F...

Page 33: ...nsors 2 Remove the packaging material To discard the packaging material refer to section 2 12 3 Make sure that all parts are delivered according to the order Refer to the order and section 12 2 4 If y...

Page 34: ...is too high do these steps For the transport specifications refer to section 12 7 a Accept the delivery of the EVSE b Make a note on the delivery receipt c If damage occured leave the item in its ori...

Page 35: ...exposed to direct sunlight and high ambient temperatures for most of the day 3 a Make sure that a circuit breaker and a residual current device are installed to protect the AC auxiliary power supply...

Page 36: ...s available for an approved service engineer and the network operating center of the manufacturer 5 2 Control the space and airflow around the EVSE 1 Make sure that the floor spaces meet the requireme...

Page 37: ...ith gravel or another substance to prevent that rodents go into the cabinet 5 4 3 Prepare a metal foundation for the power cabinet Preliminary requirements Drill with screw tap Torque wrench Metal fra...

Page 38: ...to order the cable gland plate for your EVSE Refer to section 1 11 2 Guide the cables through the cable gland plate A 3 Install the cable gland plate on the foundation B 4 Install the fasteners C that...

Page 39: ...fer to section 6 2 1 4 Do the electrical installation of the power cabinet Refer to section 6 3 1 6 2 Mechanical installation 6 2 1 Mechanical installation of the power cabinet general procedure Preli...

Page 40: ...curs when 4 or more cabinets are installed 3 Install the fasteners C and the washers 4 Tighten the fasteners to the correct torque For the specification refer to section 12 4 6 2 3 Install the cover p...

Page 41: ...Refer to section 6 3 4 e Connect the AC auxiliary output cable 1 phase 120 V to the power cabinet Refer to section 6 3 5 f Install the AC covers Refer to section 10 6 3 Open the DC door Refer to secti...

Page 42: ...cted if a collision moves the power cabinet b Strip the insulation from the end of the wire Make sure that the stripped length is compatible with the cable lug specification c Attach the cable lug C t...

Page 43: ...e correct torque For the specification refer to section 12 4 6 3 4 Connect the AC auxiliary power cable 3 phase 480 V in the power cabinet Preliminary requirements Torque screwdriver cross Wire cutter...

Page 44: ...L1 wire X3 1 B L2 wire X3 2 C L3 wire X3 3 D PE wire X4 4 2 E L1 wire X3 5 F L2 wire X3 6 G L3 wire X3 7 H PE wire X3 8 3 I L1 wire X3 9 J L2 wire X3 10 K L3 wire X3 11 L PE wire X3 12 4 M L1 wire X3...

Page 45: ...binet and the connections treated in this section For the specific connections refer to the installation brief the installation drawing and the installation manuals of the devices installed in the sys...

Page 46: ...L PE wire X3 12 4 Tighten the screws to the correct torque For the specification refer to section 12 4 6 3 6 Connect the DC power cables Preliminary requirements Torque wrench Wire cutter Wire stripp...

Page 47: ...4 DC wire marked red to the connector X525 D Outlet 4 DC wire to the connector X529 E 5 Install the nuts and washers J on the connectors 6 Tighten the nuts to the correct torque For the specification...

Page 48: ...dc gnd CP3 4 G 24V DC X7 1 24Vdc CP4 H 0V DC X7 2 0Vdc gnd CP4 6 3 8 Connect the interlock and DC guard cables to the power cabinet Preliminary requirements Interlock and DC guard cables Refer to sect...

Page 49: ...specific connections refer to the installation brief the installation drawing and the installation manuals of the devices installed in the system you ordered For information about the part numbers of...

Page 50: ...K Interlock OUT X6 3 INTERLOCK 3 OUT L Interlock IN X6 4 INTERLOCK 3 IN M DC guard signal X6 5 DC GUARD 3 N DC guard GND X6 6 DC GUARD3 GND O Ground wire or shield mesh X6 earthing terminal CP3 PE 4...

Page 51: ...o the installation brief the installation drawing and the installation manuals of the devices installed in the system you ordered For information about the part numbers of the terminals refer to secti...

Page 52: ...cable A to the output terminal D6 B Input cable C to the input terminal D6 D 3 Repeat step 2 for the other outlets to these terminals For outlet 2 connect the cables to D7 E For outlet 3 connect the c...

Page 53: ...nary requirements Procedure 1 Open the DC door Refer to section 10 7 2 Connect the optical fiber cable that replaces the ethernet cable of the outlet Refer to section 6 3 10 3 Disconnect the ethernet...

Page 54: ...which socket belongs to which outlet Outlet number of the power cabinet Socket Outlet 1 C CB 4B Outlet 2 D CB 4A Outlet 3 E CB 3B Outlet 4 F CB 3A 6 3 14 Connect the ethernet cable to the connector P...

Page 55: ...et 2 C X85 X5 8 Outlet 3 D X86 X6 8 Outlet 4 E X87 X7 8 6 3 15 Connect the EMO cable to the power cabinet optional Preliminary requirements EMO cable Note The illustration shows the terminal block X9...

Page 56: ...ter Wire stripper pliers Crimp plier Ferrule Procedure 1 Make sure that the diameter of the ferrule is correct The ferrule must be compatible with the wire Obey the technical specifications set by the...

Page 57: ...mmissioning mode 6 4 1 General information You can only start the commissioning of the power cabinet when there is a 3 phase 480 V AC power supply from the AC power grid If there is no 3 phase 480 V A...

Page 58: ...et There is no 3 phase 480 V AC power supply from the AC power grid Note If the single phase 120 V AC cable from the AC grid is not installed contact the manufacturer Refer to section 1 11 Procedure 1...

Page 59: ...liminary requirements Only do this procedure when a different procedure refers to this procedure AC single phase cable Refer to section 12 13 4 Ferrules Torque screwdriver cross Wire cutter Wire strip...

Page 60: ...Q2 Off 6 4 6 Set the precommissioning switch Preliminary requirements Only do this procedure when another procedure refers to it Procedure 1 Make sure that these fuses are serviceable F10 F21 F22 2 S...

Page 61: ...to section 7 1 2 If one or more of these conditions are false then the cabinet is out of the precommissioning mode Prepare the cabinet for commissioning Refer to section 7 2 7 1 2 General procedure Pr...

Page 62: ...1 2 Disconnect the wires A B C from the terminals 3 Tighten the screws 4 Disconnect the 120 V AC cable from the external power supply 5 Fully remove the cable from the electrical system 7 2 Prepare fo...

Page 63: ...e must be available The site operator or owner is available to receive instructions from the service engineer of the manufacturer 3 Make sure that this data is available Contact data of the contact pe...

Page 64: ...uirements in section 12 9 6 Make sure that regular maintenance is done on the EVSE Refer to section 9 1 8 2 Emergency stop A standard power cabinet does not have an emergency stop button An emergency...

Page 65: ...s on the beacon for each outlet Refer to section 3 4 1 3 If the charge session does not start contact ABB E mobility Inc 8 4 3 Stop a charge session Do this procedure to stop a charge session at any t...

Page 66: ...sive tool Refer to section 12 6 Danger Hazardous voltage Do not apply high pressure water jets Water can leak into the EVSE Note When the EVSE is put in a corrosion sensitive environment superficial r...

Page 67: ...Maintenance and cleaning HVC 200 300 360 EN 002 67...

Page 68: ...1 Turn the cover plate A 2 Insert the door key B 3 Turn the door key counterclockwise to unlock the door C 4 Pull the handle D 5 Turn the handle clockwise 6 Open the door 10 2 Close the door of the p...

Page 69: ...er plate D to cover the keyhole 10 3 Remove the plinth covers of the power cabinet Preliminary requirements Set of open spanners Procedure 1 Remove these parts Fasteners A Plinth covers B 10 4 Install...

Page 70: ...over b Install the bolts D c Tighten the bolts 10 5 Remove the AC cover Preliminary requirements The main switch is set to OFF Screwdriver Procedure 1 Loosen the fasteners and remove the lower lexan c...

Page 71: ...DC door Danger Hazardous voltage Make sure that only qualified personnel has access to the door key Procedure 1 Insert the door key in the lock A 2 Turn the door key counterclockwise to unlock the do...

Page 72: ...d personnel has access to the door key Procedure 1 Close the door 2 Insert the door key in the lock A 3 Turn the door key counterclockwise to lock the door B 4 Do step 2 and 3 again for the second loc...

Page 73: ...Try to find a solution for the problem with the aid of the information in this document 2 If you cannot find a solution for the problem contact the manufacturer or the local service unit Refer to sec...

Page 74: ...L Note The equipment is prepared with a switch matrix for dynamic charging It can be upgraded with a software update when this feature becomes available 12 1 2 HVC variants AGC code Short description...

Page 75: ...cluded in the delivery Refer to the order 12 3 Required parts for installation Part Specification Fasteners and washers to connect the charge post to the foundation M12 class A2 length 70 mm 2 75 in F...

Page 76: ...s if not specified other wise 180 132 M16 cable glands 2 1 4 M20 cable glands 4 5 3 3 M25 cable glands 5 3 6 M32 cable glands 6 4 4 M40 cable glands 10 7 3 12 5 General specifications Parameter Specif...

Page 77: ...aging B Power cabinet C Pallet Parameter Specification kg lb Mass 1000 2200 Parameter Specification mm in X1 770 30 X2 1170 46 X3 1150 45 3 X4 517 20 4 X5 633 25 X6 1250 49 2 X7 622 24 5 X8 628 24 7 Y...

Page 78: ...ed from the top of the foundation Parameter Specification mm ft in AC input cable 1000 3 4 Auxiliary AC input cable 3000 15 8 DC power cable 3000 15 8 PE cable 3000 15 8 Interlock cable 3000 15 8 DC g...

Page 79: ...et Y2 Space to open the power cabinet door Y3 Depth of the muffler Y4 Space for the foundation A Power cabinet B Back to back configuration C Side by side configuration D Side by side and back to back...

Page 80: ...12 10 1 Power cabinet custom foundation 596 174 65 172 318 354 501 689 836 872 1019 790 185 335 1190 1060 65 65 65 660 A B A Holes to install the fasteners of the power cabinet B gland plate Technical...

Page 81: ...Z1 Height of the foundation Z2 Height of the gland plate Parameter Specification mm in X1 1190 46 9 Y1 790 31 1 Z1 320 12 6 Z2 79 3 1 12 11 Ambient conditions Parameter Specification Operating temper...

Page 82: ...wer cabinet and the charging interface always connect an output terminal D to an input terminal E Do not connect terminals that are the same for example an output terminal to an output terminal 12 13...

Page 83: ...shielded Number of cores 4 Core identification Acc to IEC 60446 Cross section 2 5 mm 14 AWG Diameter 5 10 mm 0 2 0 4 in Conductor Bare copper fine wired bunch stranded acc to VDE 0295 CI 5 IEC CI 5 In...

Page 84: ...ed and oil resistant Nominal voltage Uo U 600 1000 Vac 900 1500 Vdc Minimum test voltage 6 kV Ambient temperature range 40 C to 80 C 40 F to 176 F permissi ble conductor operating temperature 90 C 194...

Page 85: ...and oher de vices 35 mm 2 AWG Conductor Fine strand copper wire according to VDE 0295 Cl 5 IEC 60228 Cl 5 Insulation PVC that is serviceable for outdoor use UV protected and oil resistant Nominal vol...

Page 86: ...e 40 C to 80 C 40 F to 176 F Strip length 11 mm 0 43 in 12 13 10 Ethernet cables Parameter Specification Type Cat6 or Cat5e shielded tinned copper braid Number of twisted pairs 4 x 2 Core identificati...

Page 87: ...ase 480 V AC PE L1 L2 L3 Input voltage range 480 V AC 10 Frequency 60 Hz 4 Maximum power dissipation 326 kVA Power factor at full load 0 95 Efficiency 94 and 96 in power spectrum be tween 20 and 100 o...

Page 88: ...720 V DC 450 A at 800 V DC 4 outlets 285 A at 700 V DC 250 A at 800 V DC 430 A at 700 V DC 375 A at 800 V DC 500 A at 720 V DC 450 A at 800 V DC Maximum output cur rent in total for the whole charg er...

Page 89: ...the duration This can only be given on a system level In the Dynamic variant the maximum output current for one outlet is available only when the sum of the output currents for all the outlets in use...

Page 90: ...er consumption specifications Parameter Specification Standby power consumption for every variant of the power cabinet 60 W 12 18 Terminal part numbers Type ABB part number Used in section Color on th...

Page 91: ...Technical data HVC 200 300 360 EN 002 91...

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ABB HVC 200, Operation And Installation Manual, Page: 30 / 92

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