ABB HVC-C 100-150 kW Installation Manual Download Page 25

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2.3.11 Control box CCS, inside

Electronics compartment

Cover

DC power busbars

Cable glands

Part

Function

Electronics compartment To house electronic boards and DIN rail

Cover

To prevent unauthorized access to the ibusbars

DC power busbars

To connect DC power cables

Cable glands

Openings for the input and output cables

Description

6AGA000007-0611-EN | 001

Summary of Contents for HVC-C 100-150 kW

Page 2: ...Copyright All rights to copyrights registered trademarks and trademarks reside with their respective owners Copyright ABB EV Infrastructure All rights reserved 2 6AGA000007 0611 EN 002 ...

Page 3: ... 14 2 1 Type plate 14 2 2 Intended use 14 2 3 Overview 15 2 3 1 Overview of the system 15 2 3 2 Power cabinet outside 16 2 3 3 Power cabinet inside 17 2 3 4 Power supply box outside 18 2 3 5 Overview of the power supply box inside 19 2 3 6 Cable glands in the power supply box 20 2 3 7 Control box CR outside 21 2 3 8 Control box CR inside 22 2 3 9 Cable glands in the control box CR 23 2 3 10 Contro...

Page 4: ...6 5 1 General installation procedure 36 5 2 Install the power cabinet general procedure 36 5 3 Install the power supply box general procedure 36 5 4 Install the control box general procedure 37 6 Site preparation 38 6 1 Prepare the site 38 6 2 Control the space and airflow around the EVSE 38 6 3 Install the cable ducts 38 7 Foundations 39 7 1 Prepare the foundation for the power cabinet 39 7 1 1 P...

Page 5: ...re 51 11 2 Prepare the wall for the control box 51 11 3 Install the brackets on the control box 51 11 4 Install the control box on the wall 52 12 Paragraph left intentionally blank 53 13 Electrical installation of the power cabinet 54 13 1 Electrical installation of the power cabinet general procedure 54 13 2 Connect the PE wires to the power cabinet 54 13 3 Connect the AC input cable 55 13 4 Conn...

Page 6: ...er cables to the control box CR 71 15 8 1 Connect the DC cables to the control box input and output to the cable reel 71 15 8 2 Connect the DC cables to the control box output to the next control box 71 15 9 Connect the DC power cables to the control box CCS 73 15 9 1 Connect the DC cables to the control box input and output to the cable reel 73 15 9 2 Connect the DC cables to the control box outp...

Page 7: ...0 Wall and ceiling mounting specifications 95 20 10 1 Power supply box wall 95 20 10 2 Control box wall 96 20 11 Ambient conditions 97 20 11 1 Power cabinet 97 20 11 2 Control box 97 20 11 3 Power supply box 97 20 12 Cable specifications 98 20 12 1 General specifications for cables 98 20 12 2 AC input cables 98 20 12 3 Auxiliary AC input cables 98 20 12 4 DC power cables 98 20 12 5 DC power cables...

Page 8: ...tion 104 20 12 2 150 kW configuration 104 20 14 DC output specifications 105 20 14 1 100 kW configuration 105 20 14 2 150 kW configuration 105 20 15 Power consumption 105 20 15 1 General specifications 150 kW configuration 105 Contents 8 6AGA000007 0611 EN 002 ...

Page 9: ... 5 Illustrations It is not always possible to show the configuration of your EVSE The illustrations in this document show a typical setup They are for instruction and description only 1 6 Units of measurement SI units of measurement metric system are used If necessary the document shows other units between parentheses or in separate columns in tables 1 7 Typographical conventions The lists and ste...

Page 10: ...ion about the condition of the EVSE before you start the procedure Requirements for personnel for a proce dure General safety instructions for a proce dure Information about spare parts that are necessary for a procedure Information about support equipment that is necessary for a procedure Information about supplies consuma bles that are necessary for a procedure Make sure that the power supply to...

Page 11: ...nt name Target group Product data sheet All target groups Installation manual Qualified installation engineer User manual Owner Service manual Qualified service engineer Declaration of conformity CE All target groups 1 12 Manufacturer and contact data Manufacturer ABB EV Infrastructure Heertjeslaan 6 2629 JG Delft The Netherlands Contact data The local representative of the manufacturer can give y...

Page 12: ...g center of the manufacturer Facility of the manufacturer to do a remote check on the correct operation of the EVSE Cabinet Enclosure of the EVSE including the components on the inside CHAdeMO Japanese DC fast charging method for electric vehicles Contractor Third party that the owner or site operator hires to do engineering civil and electrical installation work Grid provider Company that is resp...

Page 13: ... EVSE to charge the EV Note It is possible that not all terms are present in this document 1 15 Orientation agreements D C B X Z Y A A Front 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 rearward Z Z direction positive is upward About this document 6AGA000007 0611 EN 001 13 ...

Page 14: ...facturer F Full EVSE type Refer to section 20 1 G Mass of the EVSE H EVSE rating I Address of the manufacturer J CE mark K Barcode with the serial number of the EVSE L Barcode with the part number of the EVSE M Additional EVSE rating data Note The data in the illustration are only an example Find the type plate on your EVSE to see the applicable data Refer to section 20 1 2 2 Intended use The EVSE...

Page 15: ...ables Part Function AC input cable To supply the electricity from the power distribution board to the EVSE Auxiliary AC input cable To supply the electricity from the auxiliary power dis tribution board to the EVSE Power cabinet To change the AC input power into DC output power Power supply box To supply the EVSE with DC auxiliary power DC output cables To conduct the DC output from the EVSE to th...

Page 16: ...om part of the EVSE Air inlet and outlet To let the cooling air in and out The airflow prevents overheating of the parts on the inside of the EVSE Type plate To show the identification data of the power cabinet Door To give authorized personnel access of the inside of the cabinet Antenna To send and receive wireless 2G 3G and 4G signals Enclosure To reduce the accessibility of unqualified persons ...

Page 17: ...ction DC output busbars To connect the DC output power cables Cable inlet Opening for the cables PE busbar To connect PE cables AC power connector To connect to the AC input power cable Main switch To connect or disconnect the AC power X 8 terminal block To connect the interlock cables CAN2ETH board To connect the Ethernet cables Description 6AGA000007 0611 EN 001 17 ...

Page 18: ...art Function Enclosure To reduce the accessibility of unqualified persons to the inside of the EVSE Door To prevent unauthorized access to the inside of the box Cable glands Openings for the cables Type plate To show the identification data of the box Description 18 6AGA000007 0611 EN 001 ...

Page 19: ...ducts Part Function DIN rail X1 To connect these cables auxiliary AC input cable auxiliary DC power cables power supply feedback cables DIN rail X2 To connect PE cables Cable glands Openings for the input and output cables Cable duct To guide the cables to the terminals Description 6AGA000007 0611 EN 001 19 ...

Page 20: ...C input cable C Power supply feedback cable D Auxiliary DC output cable E PE from the ground band iron F PE from the control box 2 G PE from the control box 4 H PE from the control box 5 J PE from the power cabinet K PE from the control box 1 L PE from the control box 3 Description 20 6AGA000007 0611 EN 001 ...

Page 21: ... To reduce the accessibility of unqualified persons to the inside of the EVSE Door To prevent unauthorized access to the inside of the EVSE Beacon To indicate the state of the EVSE Type plate To show the identification data of the box Cable glands Openings for the cables Description 6AGA000007 0611 EN 001 21 ...

Page 22: ...use electronic boards and DIN rail DIN rail components Components such as auxiliary DC power terminals interlock and DC guard terminals Ethernet terminals interlock terminals Cover To prevent unauthorized access to the ibusbars DC power busbars To connect DC power cables Cable glands Openings for the input and output cables Description 22 6AGA000007 0611 EN 001 ...

Page 23: ...ion A B C D E F G H I A Auxiliary DC input cable B External EMO button beacon and stop button C Spare D Ethernet input cable E Interlock cable F DC input cable G CCS auxiliary signals H Cable reel interlock I DC output cable 6AGA000007 0611 EN 001 23 ...

Page 24: ...e B Door C Beacon E Cable glands Part Function Door To prevent unauthorized access to the inside of the EVSE Beacon To indicate the state of the EVSE Cable glands Openings for the cables Description E B C 24 6AGA000007 0611 EN 001 ...

Page 25: ...Cable glands Part Function Electronics compartment To house electronic boards and DIN rail Cover To prevent unauthorized access to the ibusbars DC power busbars To connect DC power cables Cable glands Openings for the input and output cables Description A D C E 6AGA000007 0611 EN 001 25 ...

Page 26: ...nterlock DC guard input cable G Extrernal EMO button beacon and stop button H Ethernet input cable J PE from the power supply box K Auxiliary DC input cable L Ethernet output cable to the next control box M Interlock DC guard output cable to the next control box N Fiber optic input cable O Auxiliary DC output cable to the next control box P CCS cable Description 26 6AGA000007 0611 EN 001 K J F N C...

Page 27: ...2 4 Control elements 2 4 1 Beacon A A Beacon with integrated LED indicator The beacon shows the status of the EVSE Table 1 Indications of the lights Description 6AGA000007 0611 EN 001 27 ...

Page 28: ...f power in case of emergency Note The placement of this button is customized for every configuration 2 5 Options 2 5 1 Stop button A A Stop button The stop button is used to stop the charge session Note The placement of this button is customized for every configuration Description 28 6AGA000007 0611 EN 001 ...

Page 29: ...VSE the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information The manufacturer is 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 3 2 General safety instructions This document th...

Page 30: ... instructions during installation Preliminary requirements 1 Do not use adaptors or conversion adapters Do not use cord extension sets Make sure that there is no voltage on the AC input cables during the complete installation procedure Keep unqualified personnel at a safe distance during installation Only use electrical wires of sufficient gauge and insulation to handle the rated current and volta...

Page 31: ...sonal protective equipment Refer to section 3 3 3 7 Safety instructions for earthing Preliminary requirements Make sure that the EVSE is connected to an earthed metal permanent electrical system Alternatively install an equipment earthing conductor with circuit conductors Connect this earthing conductor to an equipment earthing terminal or lead on battery charger Make sure that the connections to ...

Page 32: ...the manual before you install the EVSE Waste from electrical and electronic equipment Note It is possible that not all symbols are present on the EVSE 3 10 Discard parts or the EVSE Obey the local rules to discard parts packaging material or the EVSE Discard electrical and electronic equipment separately in compliance with the WEEE 2012 19 EU Directive on waste of electrical and electronic equipme...

Page 33: ...uch as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its affiliates are not liable for damages and...

Page 34: ... cabinet with a forklift truck 4 2 3 2 Move the boxes to the site 4 2 2 Hoist the cabinet Preliminary requirements 1 The cabinet is unpacked Refer to section 8 1 Hoisting equipment including cables swivel eye bolts or bolts with lifting loops Refer to section 20 3 Note Risk of pinching or crushing the cabinet is heavy Make sure that the hoisting equipment can lift the cabinet safely Obey the safet...

Page 35: ...tion 20 3 Note Risk of pinching or crushing the cabinet is heavy Make sure that the forklift truck can lift the cabinet safely Obey the safety instructions that apply to the forklift truck Take into account the mass the dimensions and the center of gravity of the EVSE Refer to chapter 20 7 Caution Do not drop the cabinet Do not tilt the cabinet more than allowed Refer to section 20 4 Procedure 1 M...

Page 36: ...t general procedure Preliminary requirements 1 The site is prepared Procedure 1 Prepare the foundation for the power cabinet Refer to section 7 1 1 2 Unpack the power cabinet Refer to section 8 1 3 Do the mechanical installation of the power cabinet Refer to section 9 1 4 Do the electrical installation of the power cabinet Refer to section 13 1 5 3 Install the power suply box general procedure Pre...

Page 37: ...nts 1 The site is prepared Procedure 1 Unpack the control box Refer to section 8 3 2 Do the mechanical installation of the control box Refer to section 11 1 3 Do the electrical installation of the control box Refer to section 15 1 Installation 6AGA000007 0603 EN 001 37 ...

Page 38: ... wireless 2G 3G 4G signal is available Refer to section 20 12 8 Contact the manufacturer if you require a specific configuration Refer to section 1 12 Note The cables enter the cabinet from the bottom If you install a long distance package the procedures about the Ethernet cables are not valid Obey the instructions about the long distance package included in a separate manual 4 Make sure that the ...

Page 39: ...fab concrete foundation Refer to section 20 9 1 Two cover plates Six fasteners M16 for the top cover plate Four fasteners M12 for the front cover plate Warning Risk of pinching or crushing the foundation is heavy Obey the safety instructions that apply to the hoisting equipment Take into account the dimensions and mass of the foundation Refer to section 20 9 1 Warning Risk of falling Cover the fou...

Page 40: ...oundation in the initial order contact the manufacturer to order the foundation for your power cabinet Refer to section 1 12 Four fasteners M16 with washers Procedure 1 Mark the position of the holes B on the ground For the specifications refer to section 20 9 2 2 Drill and thread the holes 3 Guide the cables to the cable trays C 4 Align the frame A with the threaded holes 5 Install the fasteners ...

Page 41: ...on the positions B and C For dimension specifications refer to section 20 9 3 3 Make sure that the AC power cable and other cables come out of the floor at the marked area B 4 Make sure that the DC power cables come out of the floor in the marked area C A B C Foundations 6AGA000007 0611 EN 001 41 ...

Page 42: ...P a g e l e f t i n t e n t i o n a l l y b l a n k 42 6AGA000007 0611 EN 001 ...

Page 43: ... If the sensors A show a red indication or the sensors B show a tilt that is too high do these steps For the transport specifications refer to section 4 a Refuse the delivery of the EVSE b Make a note on the delivery receipt c Within three days of the delivery ask the transport company for an inspection d If you see damage on the cabinet through the packaging material do not unpack the EVSE e Cont...

Page 44: ...Remove the cabinet from the pallet Preliminary requirements Open spanner Procedure 1 Remove the fasteners A 2 Discard the fasteners and the pallet Refer to section 3 10 A Unpacking 44 6AGA000007 0611 EN 001 ...

Page 45: ...Refer to section 18 5 9 2 Install the cabinet on the foundation Preliminary requirements Hoisting equipment or forklift truck Torque wrench Four fasteners M16 with washers Procedure 1 Carefully lower the cabinet on the foundation with a hoisting equipment or a forklift truck Refer to section 4 2 Caution Make sure that there is no kink in the cables 2 Make sure that the holes in the cabinet A and t...

Page 46: ...t Preliminary requirements 1 The cable inlets are open Procedure 1 Guide the AC input cable DC auxiliary cable interlock and CAN cables A through the opening B 2 Guide the DC output cables C through the opening D 9 5 Close the cable inlets Preliminary requirements Torque wrench B A C D A B Mechanical installation of the power cabinet 46 6AGA000007 0611 EN 001 ...

Page 47: ...Preliminary requirements 1 The cabinet is installed on the foundation Eight Torx fasteners M5 Torx screwdriver Procedure 1 Install the cover plates A and B 2 Install the fasteners C 3 Tighten the fasteners to the correct torque For the specification refer to section 20 5 9 6 2 Install the front cover plate concrete foundation Preliminary requirements 1 The cabinet is installed on the foundation Fo...

Page 48: ...ll the cover plate B on the foundation A 2 Install the fasteners C 3 Tighten the fasteners to the correct torque For the specification refer to section 20 5 A C B Mechanical installation of the power cabinet 48 6AGA000007 0611 EN 001 ...

Page 49: ...ents Spirit level Drill with bit size recommended by the manufacturer of the wall plugs Four wall plugs 12 mm for anchor screws M8x80 Procedure 1 Mark the location for the holes A on the wall Use the spirit level and make sure the holes are at the same height For dimension specifications refer to section 20 10 1 2 Drill the mounting holes 3 Insert the plugs B into the mounting holes 10 3 Install t...

Page 50: ... the wall Preliminary requirements 1 The holes in the wall are prepared Refer to section 10 2 2 The brackets are installed on the box Refer to section 10 3 Four anchor screws M8x80 Torque screwdriver Spirit level Procedure 1 Hold the box against the wall 2 Align the holes in the brackets A installed horizontally or vertically with the holes in the wall B 3 Install the mounting screws C 4 Tighten t...

Page 51: ...irit level Drill with bit size recommended by the manufacturer of the wall plugs Four wall plugs 12 mm for anchor screws M8x80 Procedure 1 Mark the location for the holes A on the wall Use the spirit level and make sure the holes are at the same height For dimension specifications refer to section 20 10 2 2 Drill the mounting holes 3 Insert the plugs B into the mounting holes 11 3 Install the brac...

Page 52: ...ll the control box on the wall Preliminary requirements 1 The holes in the wall are prepared Refer to section 11 2 Four anchor screws M8x80 Torque screwdriver Spirit level Procedure 1 Hold the box against the wall 2 Align the holes in the brackets A with the holes in the wall B 3 Install the mounting screws C 4 Tighten the screws to the correct torque For the specification refer to section 20 5 A ...

Page 53: ...12 Paragraph left intentionally blank Paragraph left intentionally blank 6AGA000007 0611 EN 001 53 P a r a g r a p h l e f t i n t e n t i o n a l l y b l a n k ...

Page 54: ... Refer to section 18 5 Connect the AC input cable Refer to section 13 3 Install the plate and the covers Refer to section 18 6 4 Connect the DC power cables to the power cabinet Remove the DC busbar covers Refer to section 18 7 Connect the DC power cables to the power cabinet Refer to section 13 4 Install the DC busbar cover Refer to section 18 8 5 Connect the interlock cable to the power cabinet ...

Page 55: ... a nut F on the bolt C from the bottom 7 Tighten the nuts to the correct torque For the specification refer to section 20 5 13 3 Connect the AC input cable Preliminary requirements Torque wrench Wire cutter Wire stripper pliers AC input cable Refer to section 20 12 2 Wire end rings M12 Procedure 1 Prepare the wires a Cut the AC power cables so that they reach the busbar bolts A b Strip the insulat...

Page 56: ...ip length agrees with the wire end rings 3 Attach the wire end rings to the end of the wires 4 Remove the nuts and washers E from the bolts of the busbars A and B 5 Connect these wires DC wire C marked red to the connector A DC wire D to the connector B 6 Install the nuts and washers E on the connector block bolts 7 Tighten the nuts to the correct torque For the specification refer to section 20 5...

Page 57: ...erlock in wire C from the interlock out of the control box brown to the terminal X8 14 G c Interlock loop 2 out wire D to the interlock in of the control box white to the terminal X8 15 H d Wire loop E between the terminals X8 6 M and X8 7 L e Wire loop F between the terminals X8 10 O and X8 11 N 6 Tighten the terminal screws to the correct torque For the specification refer to section 20 5 13 6 C...

Page 58: ...14 3 b Auxiliary AC input cable to the power supply box Refer to section 14 4 c Power supply feedback cable to the power supply box Refer to section 14 6 d Auxiliary DC power cables to the power supply Refer to section 14 5 4 Close the door of the power supply box Refer to section 18 10 14 2 Insert the cables to the power supply box Preliminary requirements Torque wrench Auxiliary AC input cable R...

Page 59: ... Connect the PE cables in the power supply box Preliminary requirements Torque screwdriver Wire cutter Wire stripper pliers Crimp pliers Ferrules PE wires Refer to section 20 12 6 Procedure 1 Strip the insulation from the end of the cables A to G For the specification refer to section 20 12 6 2 Crimp ferrules on the ends of the wires 3 Loosen the screws on the terminals H to N B A M K GE O C N L J...

Page 60: ...specifciation refer to section 20 5 14 4 Connect the auxiliary AC input cable to the power supply box Preliminary requirements Wire cutter Wire stripper pliers Torque screwdriver cross Crimp pliers AC auxiliary input cable Refer to section 20 12 3 Ferrules Procedure 1 Strip the insulation from the end of the cable A 2 Strip the insulation from the wires B C and D For the specification refer to sec...

Page 61: ...en the screws on the terminals D and E 5 Connect these wires 0V DC wire B to the terminal X1 7 D 24V DC wire C to the terminal X1 5 E 6 Tighten the screws to the correct torque For the specification refer to section 20 5 14 6 Connect the power supply feedback cable to the power supply box Preliminary requirements Torque screwdriver Wire cutter Wire stripper pliers Crimp pliers Power supply feedbac...

Page 62: ...the twisted shield 3 Loosen the screws on the terminals G to K 4 Connect these wires a Shield B to the terminal X1 15 G b PS1_OK 14 C to the terminal X1 12 H c PS1_OK 13 D to the terminal X1 11 I d OVP_AC_11 E to the terminal X1 14 J e OVP_AC_14 F to the terminal X1 13 K 5 Tighten the screws to the correct torque For the specification refer to section 20 5 B J H G I K F E D C A Electrical installa...

Page 63: ...to section 15 4 c Ethernet cables to the control box Refer to section 15 5 d Interlock and DC guard cables to the control box Refer to section 15 6 e Power supply feedback cable to the control box Refer to section 15 7 f DC power cables to the control box CR Refer to section 15 8 g DC power cables to the control box CCS Refer to section 15 9 h Connect the cable reel interlock cable CR 15 10 i Conn...

Page 64: ...in the daisy chain two pairs Refer to section 20 12 4 Procedure 1 Loosen the nuts A of the cable glands 2 Insert the cables B through the glands For the overview of glands refer to section 2 3 9 3 Slide the nuts of the cable glands over the cables 4 Tighten the nuts to the correct torque For the specifciation refer to section 20 5 15 3 Connect the PE cables in the control box Preliminary requireme...

Page 65: ...6 Tighten the nuts to the correct torque For the specification refer to section 20 5 15 4 Connect the DC auxiliary power cables to the control box 15 4 1 Connect the DC auxiliary power input cable to the control box Preliminary requirements Torque screwdriver Wire cutter Wire stripper pliers Crimp pliers DC auxiliary cable Refer to section 20 12 5 Ferrules Procedure 1 Strip the insulation from the...

Page 66: ... the end of the cable A 2 Strip the insulation from the ends of the wires B and C For the specification refer to section 20 12 5 3 Crimp ferrules onto the end of the wires 4 Loosen the screws on the terminals D and E 5 Connect these wires 0V DC wire B to the terminal X1 6 D 24V DC wire C to the terminal X1 4 E 6 Tighten the screws to the correct torque For the specification refer to section 20 5 1...

Page 67: ... 12 7 Ferrules If there are no more control boxes in the daisy chain wire loop Procedure 1 Strip the insulation from the cable A For the specification refer to section 20 12 7 2 Prepare the wires a Twist the shield mesh B b Strip the wires C and D For the specification refer to section 20 12 7 c If there are no more control boxes in the daisy chain prepare a wire loop H d Crimp a ferrule onto the ...

Page 68: ...nsulation from the cable A For the specification refer to section 20 12 9 2 Prepare the wires a Twist the shield mesh B b Strip the wires C to F For the specification refer to section 20 12 9 c Crimp ferrules onto the end of the wires and the shield 3 Loosen the screws on the terminals G to L 4 Connect these wires a Shield B to the terminal X1 8 G b Interlock out C to the next interlock in of the ...

Page 69: ...ts 4 Loosen the screws on the terminals G to L 5 Connect these wires a Shield B to the terminal X1 9 G b Interlock out C to the interlock in of the next control box white to the terminal X1 13 H c Interlock in D from the interlock out of the next control box brown to the terminal X1 12 J d DC_Guard_A F yellow to the terminal X1 16 K e DC_Guard_GND E green to the terminal X1 17 L 6 Tighten the scre...

Page 70: ...s onto the end of the wires and the shield 3 Loosen the screws on the terminals G to L 4 Connect these wires a Shield B to terminal X1 47 G b PS1_OK 14 C blue to terminal X1 46 L c PS1_OK 13 D black to terminal X1 45 J d OVP_AC_11 E yellow to terminal X1 43 K e OVP_AC_14 F gray to terminal X1 44 H 5 Tighten the screws to the correct torque For the specification refer to section 20 5 G L H K J F C ...

Page 71: ...s C to the end of the wires 3 Connect these cables on the bolts a DC input cable J on the bolt on the negative busbar F b DC input cable H on the bolt on the positive busbar E c DC cable K to the cable reel on the bolt on the negative busbar G d DC cable L to the cable reel on the bolt on the positive busbar D 4 Install washers B and nuts A on the bolts 5 Tighten the nuts to the correct torque For...

Page 72: ...sure that the strip length agrees with the wire end rings C c Attach wire end rings C to the end of the wires 3 Connect these cables a DC cable G on the bolt on the negative busbar E b DC cable F on the bolt on the positive busbar D 4 Install washers B and nuts A on the bolts 5 Tighten the nuts to the correct torque For the specification refer to section 20 5 C D E F G B A B Electrical installatio...

Page 73: ...ees with the wire end rings C c Attach wire end rings C to the end of the wires 3 Connect these cables on the bolts a DC input cable J on the bolt on the negative busbar F b DC input cable H on the bolt on the positive busbar E 4 Install washers B and nuts A on the bolts 5 Tighten the nuts to the correct torque For the specifciation refer to section 20 5 15 9 2 Connect the DC cables to the control...

Page 74: ...sure that the strip length agrees with the wire end rings C c Attach wire end rings C to the end of the wires 3 Connect these cables a DC cable G on the bolt on the negative busbar E b DC cable F on the bolt on the positive busbar D 4 Install washers B and nuts A on the bolts 5 Tighten the nuts to the correct torque For the specification refer to section 20 5 C D E F G B A B Electrical installatio...

Page 75: ...he wires a Twist the shield mesh b Strip the wires For the specification refer to section 20 12 11 3 Make sure that any unused wires are insulated and cannot touch metal parts 4 Loosen the screws on the terminals L M 5 Connect these wires a X1 41 L DC 24V to cable reel interlock b X1 42 M NC to cable reel interlock 6 Tighten the screws to the correct torque For the specification refer to section 2...

Page 76: ...CS Temp2_2 to cable reel N O P Q R S Procedure 1 Strip the insulation from the cable For the specification refer to section 20 12 12 2 Prepare the wires a Twist the shield mesh b Strip the wires For the specification refer to section 20 12 12 3 Make sure that any unused wires are insulated and cannot touch metal parts 4 Loosen the screws on the terminals N O P Q R S 5 Connect these wires 6 Tighten...

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Page 78: ...n If the EVSE has more than one connection type an EV of each type must be available The site operator or owner is available to receive instructions from the service engineer of the manufacturer 3 Make sure that these data are available Contact data of the contact person on site Address of the EVSE Site name Exact location of the EVSE longitude and latitude If there are more EVSEs on one location ...

Page 79: ...P a g e l e f t i n t e n t i o n a l l y b l a n k 6AGA000007 0611 EN 001 79 ...

Page 80: ...There is one unique door key for each power cabinet Procedure 1 Unlock the lock A of the door B Use the door key 2 Open the door 18 2 Close the door of the power cabinet Preliminary requirements Door key to the power cabinet Danger Hazardous voltage Make sure that only qualified personnel has access to the door key Note There is one unique door key for each cabinet B A Access to parts 80 6AGA00000...

Page 81: ...covers of the power cabinet Preliminary requirements Set of open spanners Procedure 1 Remove these parts Fasteners A Border covers B 18 4 Install the covers Preliminary requirements Set of open spanners Four nuts with washers M6 C four bolts M5 D B A B A B A Access to parts 6AGA000007 0611 EN 001 81 ...

Page 82: ... a Install the cover b Install the bolts D c Tighten the bolts 18 5 Remove the plate and the covers Preliminary requirements Screwdriver cross Procedure 1 Remove the fasteners A 2 Remove the plate B 3 Remove the covers from the terminals C 18 6 Install the plate and the covers Preliminary requirements Screwdriver croess Three fasteners M5 B D A C C B A Access to parts 82 6AGA000007 0611 EN 001 ...

Page 83: ... the fasteners C 18 7 Remove the DC busbar cover Preliminary requirements Screwdriver cross Procedure 1 Remove the fasteners A 2 Remove the cover B 18 8 Install the DC busbar cover Preliminary requirements Screwdriver cross Four fasteners M5 A B C A B A Access to parts 6AGA000007 0611 EN 001 83 ...

Page 84: ...reliminary requirements Door key Danger Dangerous voltage Make sure that only qualified personnel has access to the door key Note There is one unique door key for each box Procedure 1 Unlock the lock A of the door B Use the door key 2 Open the door B B A A A B Access to parts 84 6AGA000007 0611 EN 001 ...

Page 85: ...key Danger Hazardous voltage Make sure that only qualified personnel has access to the door key Note There is one unique door key for each box Procedure 1 Close the door A 2 Lock the lock B of the door Use the door key B A Access to parts 6AGA000007 0611 EN 001 85 ...

Page 86: ...ng procedure 1 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 Refer to section 1 12 Troubleshooting 86 6AGA000007 0611 EN 001 ...

Page 87: ...150 kW Type of charging Overnight 20 2 Parts included in the delivery Part Specification 1 power cabinet 100 kW or 150 kW Refer to the type plate Refer to section 2 1 Key to the power cabinet doors Unique for each power cabinet 1 power supply box Refer to the type plate Refer to section 2 1 Key to the power supply box Unique for the box 1 to 5 control boxes Refer to the type plate Refer to section...

Page 88: ...nd 5 5 mm Torque screwdrivers Size 2 5 mm 5 mm and 5 mm Wire cutter Standard Crimp pliers Standard Wire stripper pliers Standard 20 4 Transport specifications Parameter Specification Maximum tilt angle during transport 30 20 5 Torque specifications Table 2 Torque specifications for fasteners Parameter Specification Nm lb in Power cabinet nuts on PE busbars 30 265 52 Power cabinet nuts on the AC po...

Page 89: ... Parameter Specification Nm lb in M16 2 M20 4 5 M25 5 M32 6 M40 10 20 6 General specifications Parameter Specification Compliance and safety CE IP rating The type plate shows the specification Refer to section 2 1 IK rating according to IEC 62262 enclo sure IK10 EMC rating Class B 20 7 Dimensions 20 7 1 Power cabinet Parameter Specification mm Width X dimension 1170 Depth Y dimension 770 Height Z ...

Page 90: ...kg CCS Parameter Specification mm Required cable slack for the PE cable measured from the top of the founda tion 3000 Required cable slack for the Ethernet ca ble measured from the top of the foun dation 3000 Required cable slack for the DC output cable measured from the top of the foundation 3000 Required cable slack for the DC auxiliary cable measured from the top of the foundation 3000 Required...

Page 91: ...equired for air inlet on the side Y1 Total depth Y2 Space to open the power cabinet door Y3 Space for air outlet Setting with power cabinets side by side Parameter Specification mm X1 1000 n x 1170 where n is the number of power cabinets X2 100 Y1 2070 Y2 1200 Y3 100 Technical data 6AGA000007 0611 EN 001 91 ...

Page 92: ... foundation Z1 Height of the foundation X2 Width of the hole Y2 Depth of the hole Z2 Height of the hole Z3 Distance of the foundation above the ground level Z4 Height of the layer of concrete Z5 Difference in height between the front part and the rear part of the foundation Parameter Specification X1 1300 mm Y1 1170 mm Z1 740 mm X2 1330 mm Y2 1670 mm Z2 885 mm Z3 15 mm Z4 200 mm Z5 20 mm Weight 13...

Page 93: ...X1 Width of the foundation Y1 Depth of the foundation Z1 Height of the foundation X2 Distance between the holes X3 Distance between the hole and the edge of the footprint Y2 Distance between the holes Y3 Distance between the hole and the edge of the footprint Parameter Specification mm X1 1170 Y1 766 Z1 180 X2 1050 X3 60 Y2 655 Y3 55 5 Technical data 6AGA000007 0611 EN 001 93 ...

Page 94: ...oles to install the fasteners of the power cabinet B Hole for the AC cables C Hole for the DC cables Parameter Specification mm A For M16 fasteners depth 60 B 390 x 230 C 390 x 230 X1 1050 X2 60 X3 390 Y1 680 Y2 20 Y3 230 Technical data 94 6AGA000007 0611 EN 001 ...

Page 95: ...ically X1 Distance between the holes horizontal Z1 Distance between the holes vertical Note Install all brackets either horizontally or vertically Table 4 With brackets installed horizontally Parameter Specification mm X1 658 6 Z1 330 Table 5 With brackets installed vertically Parameter Specification mm X1 530 Z1 458 6 Technical data 6AGA000007 0611 EN 001 95 ...

Page 96: ...the holes horizontal Z1 Distance between the holes vertical Note Install all brackets either horizontally or vertically Table 6 With brackets installed horizontally Parameter Specification mm X1 658 6 Z1 380 Table 7 With brackets installed vertically Parameter Specification mm X1 530 Z1 508 6 Technical data 96 6AGA000007 0611 EN 001 ...

Page 97: ...vel 20 11 2 Control box Parameter Value Ingression protection IP65 Operating temperature 35ºC to 45ºC Storage temperature 10 C to 70 C Storage conditions Indoor dry Relative humidity 5 95 non condensing Altitude Max 2000 m above sea level 20 11 3 Power supply box Parameter Value Ingression protection IP65 Operating temperature 35ºC to 45ºC Storage temperature 10 C to 70 C Storage conditions Indoor...

Page 98: ...ameter of the phase conductors Refer to the local rules Diameter of the PE conductor The same as the diameter of the phase con ductors Maximum diameter of the cable conductor 240 mm Strip length 20 mm 20 12 3 Auxiliary AC input cables Parameter Specification Cable shielding optional If the local rules require shielded cables the cable shielding must be connected to the PE rail at both ends of the ...

Page 99: ... cables between the power cabinet and the control box is between 100 and 150 m you need to install a long distance package The long distance package is included in a separate manual Ask the manufacturer Technical data 6AGA000007 0611 EN 001 99 20 12 5 DC power cables output to Cable Reel Parameter Specification Type 1x positive 1x negative cable 1x earth cable Number of cores 3x70 mm Diameter rang...

Page 100: ...hielded tinned copper braid Number of pairs 1 x 2 Core identification Acc to DIN 47100 Cross section 0 75 2 5 mm Diameter 5 10mm Conductor Fine strand copper wire Insulation PVC that is serviceable for outdoor use UV protected and oil resistant Characteristic impedance 120 Ω 10 Test voltage 1 5 kV Ambient temperature range 40ºC to 80ºC Strip length 11 mm 20 12 8 Ethernet cables Parameter Specifica...

Page 101: ...otected and oil resistant Characteristic impedance 120 Ω 10 Test voltage 1 5 kV Ambient temperature range 40ºC to 80ºC Strip length 11 mm 20 12 10 Power supply feedback cable Parameter Specification Type Shielded tinned copper braid Number of twisted pairs 2x2 Core identification Acc to DIN 47100 Cross section 0 75 mm Diameter 5 10 mm Conductor Fire strand copper wire Insulation PVC that is servic...

Page 102: ...0 Ω 10 Test voltage 1 5 kV Ambient temperature range 40ºC to 80ºC Strip length 11 mm 20 12 12 CCS control cable from the cable reel Parameter Specification Type Shielded tinned copper braid Number of twisted pairs 3x2 Core identification Acc to DIN 47100 Cross section 0 75 1 5 mm Diameter 10 14 mm Conductor Fire strand copper wire Insulation PVC that is serviceable for outdoor use UV protected and...

Page 103: ...s section 2 5 10 mm Diameter 10 14mm Conductor Bunch stranded in bare copper fine wired according to VDE 0295 Cl 5 IEC Cl 5 Insulation PVC that is serviceable for outdoor use UV protected and oil resistant Nominal voltage Uo U 450 750 Vac Minimum test voltage 4 kV Ambient temperature range 40 ºC to 80 ºC Strip length 11 mm Note Calculate the cable cross section to guarantee the voltage drop below ...

Page 104: ... AC Nominal input current 159 A AC Short circuit capacity 25 kA AC power connection 240 mm max 20 13 2 150 kW configuration Parameter Specification Input AC power connection 3 phase 400 V AC PE L1 L2 L3 Input voltage range 400 VAC 10 Frequency 50 Hz 4 Maximum power dissipation 174 kVA Power factor at full load 0 95 Efficiency 94 and 96 in power spectrum be tween 20 and 100 of full power Maximum in...

Page 105: ...ut current 167 A DC 20 14 2 150 kW configuration Parameter Specification Maximum output power 150 kW Output voltage range CCS 150 850 V DC Maximum output current 200 A DC 20 15 Power consumption 20 15 1 General specifications 150 kW configuration Parameter Specification Standby power consumption of the power cabinet 60 W Technical data 6AGA000007 0611 EN 001 105 ...

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ABB HVC-C 100-150 kW, Installation Manual

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