ABB HVC-R 100 Installation Manual Download

Page: 76 / 131

HVC-R 100/150 E-Bus Charger Installation Guide

Document: v0.4 / Document No.: TBA | Date: 11-08-2021 Page

131

5.8. Connecting Interlock cable to the Power Cabinet

Prerequisites:



Tools: wire cutter, wire stripper pliers, screwdriver, ferrules, crimp pliers.

DANGER

Make sure that the main switch of the power supply group for the product
is set to the

OFF

position.

Do a voltage check

to make sure that the

electrical power is disconnected from the system. Secure against
resetting.



Route the cable to the terminal blocks:

Preferred cable route

Route the Interlock cable to the terminal block (A). Refer to the figure for the preferred cable
route inside the cabinet.

Summary of Contents for HVC-R 100

Page 1: ... INSTALLATION GUIDE HVC R 100 150 E Bus Charger Installation Guide for EU products Version 0 4 ...

Page 2: ...ors that may appear in this document In no event shall ABB be liable for direct indirect special incidental or consequential damages of any nature or kind arising from the use of this document nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document This document is originally written in English Other language versions ...

Page 3: ...Standard HVC R 150 E Bus Charger with one Dual Depot Charge Box 14 2 1 7 Standard HVC R 150 V2 E Bus Charger with one Dual Depot Charge Box 14 2 1 8 Standard HVC R 150 V2 E Bus Charger with one Dual Depot Charge Box 14 2 1 9 HVC Power Cabinet 15 2 1 10 Dual Depot Charge Box 16 2 2 Accessories 18 2 2 1 Foundation of Power Cabinet 18 2 2 2 Pedestal of the Dual Depot Charge Box 19 2 2 3 Foundation of...

Page 4: ...net with a forklift truck 58 5 5 Installing the Power Cabinet onto a foundation 59 5 5 1 Connecting Power Cabinet to a foundation 59 5 5 2 Opening the door of the Power Cabinet 61 5 5 3 Loosening the sliding plate of the guidance plates 62 5 5 4 Routing cables through the guidance plates 62 5 5 5 Tightening sliding plates of the guidance plates 63 5 5 6 Installing border covers of the Power Cabine...

Page 5: ...ecting the InterLock cable to the next Dual Depot Charge Box 101 5 14 11 Connecting the communication Ethernet cable input 102 5 14 12 Connecting the communication Ethernet cable output 103 5 14 13 Connecting external EMO Beacon and Stop button cables optional 104 5 14 14 Installing the protection cover 107 5 14 15 Closing the door of the Dual Depot Charge Box 108 5 14 16 Reattaching rear cover pl...

Page 6: ...ated current loop and is a feature that makes the state of two mechanisms or functions mutually dependent LAN A computer network that interconnects computers systems within a limited area NOC ABB Network Operating Centre remotely checks the correct functioning of the charger Owner The legal Owner of the charger PE Protective Earth PPE Personal Protective Equipment Equipment such as safety shoes he...

Page 7: ...fully and attentively Follow the instructions presented in the Installation Guide ABB is not responsible for any damage that could be caused by not or incorrectly following and executing the instruction described in this manual 1 2 Intended document users This document is intended to be used by Customers who purchased an HVC R 100 150 E Bus Charger or currently are in the process of ordering and w...

Page 8: ... are required To operate the charge station with the protective devices installed and to make sure all protective devices are correctly installed after carrying out installation or maintenance To prepare a plan containing instructions on actions to be taken in case of an emergency To prepare the site where the charge station will be installed according to the requirements described in this guide T...

Page 9: ... operation of mobile cranes ML 03 9Akk104941D0113 WARNING Personal safety PPE Always wear a safety helmet safety gloves and safety shoes when you perform the work that involves lifting and tilting the equipment WARNING Make sure that personnel cannot be crushed or become trapped during lifting and tilting work Lifting activities It is a legal requirement that all activities involving lifting equip...

Page 10: ...nstallation disassembly repair or replacement of components 2 Do a voltage check and make sure that the electrical power is disconnected from the system 3 Only ABB certified technicians are permitted to commission the HVC R 100 150 E Bus Charger 4 When the system is in an open or dangerous state do not allow unqualified personnel near it Instruct and warn people in the vicinity about the potential...

Page 11: ...arger 1 6 Cyber Security Disclaimer This product is designed to be connected to and to exchange information and data via a network interface It is customer s sole responsibility to provide and continuously ensure a secure connection between the product and customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited...

Page 12: ...Contact information ABB in your country Please contact ABB in your country for delivery and service information ABB EV Infrastructure global ABB EV Infrastructure Address Heertjeslaan 6 2629 JG Delft The Netherlands Telephone 31 88 440 46 00 Mail info evi nl abb com Write down here your local ABB contact details ...

Page 13: ...rd delivery system configurations 1 Standard HVC R 100 E Bus Charger with one Dual Depot Charge Box 2 Standard HVC R 100 E Bus Charger with two or three Dual Depot Charge Boxes 3 Standard HVC R 100 V2 E Bus Charger with one Dual Depot Charge Box 4 Standard HVC R 100 V2 E Bus Charger with two or three Dual Depot Charge Boxes 5 Standard HVC R 150 E Bus Charger with one Dual Depot Charge Box 6 Standa...

Page 14: ...ot Charge Box ABB6AGC102131 2 1 5 Standard HVC R 150 E Bus Charger with one Dual Depot Charge Box The following parts are provided for this system configuration 1x HVC R 150 Power Cabinet ABB6AGC100794 1x Dual Depot Charge Box ABB6AGC102131 2 1 6 Standard HVC R 150 E Bus Charger with one Dual Depot Charge Box 1x HVC R 150 Power Cabinet ABB6AGC100794 2x or 3x Dual Depot Charge Box ABB6AGC102131 2 1...

Page 15: ... Base cover D 3G Antenna B Air outlet E Air inlets also on the left and back side C Door F Door handle lock Inside view of the HVC 100 150 Power Cabinet Overview of the open Power Cabinet A Main switch D Data communication connection B AC Power connection E Display C Guidance plate of the cables F Power Modules only two are installed in the HVC 100 2 Two 50 kW Power Modules installed in the cabine...

Page 16: ... Outside view of the Dual Depot Charge Box A Charge state indicator light 1 beacon G Hanging bracket for charge cable 2 B Door H CCS DC plug and cable 2 C Stop button 1 I Stop button 2 D Emergency stop button EMO J Lock and door handle E CSS DC plug and cable 1 K Charge state indicator light 2 beacon F Hanging bracket for charge cable 1 ...

Page 17: ... Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 17 of 131 Inside view of the Dual Depot Charge Box A Communication connection B Connection block C Protection cover for DC contactors ...

Page 18: ... install the Power Cabinet on soil Elements of Power Cabinet s concrete foundation A Foundation B Top cover plate C Front cover plate Amount Part number Description 1 ABB6AGC069029 HxC power cabinet foundation front cover plate 1 ABB6AGC067780 HxC power cabinet foundation top cover plate Metal frame foundation The metal frame foundation can be used to install the Power Cabinet on a solid surface E...

Page 19: ...21 Page 19 of 131 2 2 2 Pedestal of the Dual Depot Charge Box The pedestal can be used to attach the Dual Depot Charge Box in the open when it is not being mounted on a wall Overview of Dual Depot Charge Box s pedestal Amount Part number Description 1 ABB6AGC102301 HVC R pedestal charge box ...

Page 20: ...e 20 of 131 2 2 3 Foundation of the pedestal The concrete foundation must be used to install the pedestal on soil Overview of pedestal s concrete foundation A Cable conduit outputs B Cable conduit inputs Amount Part number Description 1 ABB6AGC103612 HVC R concrete foundation Dual Depot Charge Box ...

Page 21: ...the Power Cabinet and Dual Depot Charge Boxes is achieved via an Ethernet cable If the cable is not supplied by ABB then gland dimensions listed in section Gland layout of the Dual Depot Charge Box on Page 89 must be followed Please note that special precautions should be taken so that pre fabricated the cable could pass through the gland for example order cable with M25 gland assembled on it Anot...

Page 22: ...mpleted before the Contractor can perform the civil and electrical works See About preparation on Page 23 B Construction The Contractor performs all civil and electrical works See About construction on Page 37 C Placement and Connection The location is mechanically and electrically ready to receive the HVC R 100 150 E Bus Charger See About placement and connection on Page 52 D Commissioning The de...

Page 23: ... i a drawings calculations certifications licenses and test reports The location of the HVC R 100 150 E Bus Charger must be selected See section Location on Page 27 and section Geometry of infrastructure on Page 28 A3 Get permits Make sure that all the permits required by local regulations had been acquired See section Required permits on Page 24 A4 Upgrade grid If required upgrade the electrical ...

Page 24: ...abinet and the cables connecting the Power Cabinet and the ACS Control Module Contact your electricity Retailer and or Grid Owner if a grid upgrade is required Ask about the work that is needed to upgrade the connection to meet the requirements described in section Electrical installation on Page 33 3 3 2 Construction permit The installation of the HVC R 100 150 E Bus Charger requires performing t...

Page 25: ...ervice department There are two available options for the Internet connection Wireless which requires coverage of a 3G network at the location This is the preferred connection A 3G modem with active SIM card is included with the HVC R 100 150 E Bus Charger a customer SIM card is not required Ethernet RJ45 If there is no 3G signal available a wired internet connection must be available at the locat...

Page 26: ...ng parts must be determined by your electrical engineer They depend on local laws safety and electrical regulations Adjustable RCD in the range of 30 mA up to 300 mA The Power Cabinet has an integrated 300 mA RCD Type A for the power section Class 1 Surge Protection Device SPD The Dual Depot Charge Box can be connected directly to the electrical grid or to an existing customer low voltage power di...

Page 27: ...ximum temperature Do not install or use the HVC R 100 150 E Bus Charger in areas where there is an explosion hazard You must provide information about the HVC R 100 150 E Bus Charger to the fire brigade The protection rating of the housing of the Power Cabinet is IP54 and the Dual Depot Charge Box is IP65 excluding charge cable and designed for outdoor use It is recommended to provide good lightin...

Page 28: ...s placed indoors consider designating additional free space in front of the open door escape way for service people CAUTION The cabinet needs at least the opening area of the front and rear side with a minimum free distance of 100 mm This means that cabinets can stand in a row with one or both side entries blocked distance on left right side is 0 mm It is also possible for the cabinets to stand ba...

Page 29: ...ssure drop of the room is higher than 300 Pa an extra fan should be placed Contact ABB Sales department see Contact information on Page 12 for contact details 3 6 2 Placement of multiple Power Cabinets There are two possible configurations for the placement of multiple HVC 150 systems see picture below Possible placements of multiple Power Cabinets The Power Cabinets can be placed back to back or ...

Page 30: ...s of a Dual Depot Charge Box s footprint 600 x 250 mm W x D The unoccupied space of following dimensions 0 mm at the rear side when the Dual Depot Charge Box is mounted directly to a wall or a minimum of 100 mm at the rear side when the Dual Depot Charge Box is in front of a wall and mounted to the pedestal 500 mm on the left and right sides to allow operation of the charger plugs 900 mm on the fr...

Page 31: ...e some useful information about the placement of a charger with respect to parking spaces and the different vehicle inlets for the charging cable 3 7 1 Cable reach The DC charge cable of the Dual Depot Charge Box is about 7 meters long The picture below shows an indication of the reach of one of the outlet cables with respect to the Dual Depot Charge Box located in the center of the picture Indica...

Page 32: ...s have their inlets located at the front or the back of the vehicle either on one of the sides or centrally as indicated below Most common locations of a bus s charge inlets This makes some positions of the charger more favorable than others regarding the desired arrangement of the parking space Please keep this in mind when designing a site Some possible situations are shown in the picture below ...

Page 33: ...ower Cabinet is shown in the figure below The diameter of the electrical conductor maximum cross section is 240 mm2 in the AC power cable depends on the length and method of installation This must be determined by your Contractor Diagram of the Power Cabinet s electrical connection There are two options of connection of the AC auxiliary power supply for the Dual Depot Charge Boxes to the electrica...

Page 34: ...rger is located indoors the cables can be led above the ground level In this case the presence of cables trays is required to protect the cables The most suitable option should be chosen by the Contractor performing the works as this matter is not resolved in this Installation Guide DC power cables PE wire and data cables must be routed between the Power Cabinet and the Dual Depot Charge Box There...

Page 35: ...cables E AC power cable for the Power Cabinet Example of civil installation when the Dual Depot Charge Box is mounted on a wall A Foundation of the Power Cabinet B Wall on which the Dual Depot Charge Box will be mounted C Flexible conduit for DC power cables D Flexible conduit for AC auxiliary power PE wire and data cables E AC power cable for Power Cabinet NOTICE Document the location of all the ...

Page 36: ...grid is TT based consult the grid Owner It is possible that an extra 0 9 Ω electrode will be required This requirement must be determined by the Contractor Consult a local specialist for the options of lightning protection The charge system has to be within the protection angle of the lightning distraction This requirement must be determined by the Owner and a local specialist according to NEN EN ...

Page 37: ...on of Construction phase on the planning diagram B1 Civil engineering works Construction of the foundation see section Providing foundation for the Power Cabinet on Page 38 and section Mounting of the Dual Depot Charge Box on Page 43 Installation of the cable connections see section Cable routing on Page 46 Construction of the bus stop surrounding see section Geometry of infrastructure on Page 28 ...

Page 38: ...crete Foundation Solid floor 1 Use a metal frame foundation to guide the cables from the cabinet to the cable duct This foundation can be ordered separately See section Accessories on Page 18 For detail drawings see Appendix D Dimensions of the Power Cabinet s Metal Foundation 2 The Power Cabinet is installed directly on a solid floor through which the floor is accessible from below related to the...

Page 39: ...ome out of the foundation with a length of about 250 mm 4 Make sure that the AC power cable is routed to one of the indicated positions B 5 Lower the foundation A into the hole 6 Make sure that the front top surface of the foundation is at least 15 mm above ground level see figure above 7 Make sure that the top surface of the foundation is leveled 8 Route the conduits through one of the eight hole...

Page 40: ...ocations of the foundation 12 Secure the top cover plate with M16 bolts 4x and the front cover plate with M12 bolts 4x WARNING These cover plates are required to prevent people from falling into the foundation 13 Fill the open space in the ground around the foundation and the channels for the conduits with filling material e g sand Filling material is packed 2 3 times with a packing machine until ...

Page 41: ... of the Power Cabinet s Metal Foundation 2 Remove the frame 3 Drill and tap holes at the marked positions The holes must be suitable for bolt size M16 4 Route the cables tray through one of the cable openings B 5 Align the frame A with the tapped holes 6 Insert the bolts C fitted with the washers D into the holes 4x 7 Tighten the bolts 8 Route the AC power cable through the left cable opening B Ma...

Page 42: ... the other cables come out of the floor within the marked area B 4 Make sure that the DC power cables come out of the floor within the marked areas C 5 For the AC and DC power cable make sure that a cable length of 1 m is available above the floor for internal routing inside the cabinet 6 For the other cables make sure that a cable length of 3 m is available above the floor for internal routing in...

Page 43: ...al Dimensions necessary for civil installation of the foundation All dimensions given in mm WARNING Make sure that personnel cannot be crushed or become trapped while moving the foundation Be aware that the weight of the concrete foundation is about 535 kg CAUTION Before you lower the foundation remove sharp edges of the cable holes B in the foundation to protect the cables 1 Prepare a hole in the...

Page 44: ...foundation is at least 15 mm above ground level see figure above 8 Make sure that the top surface of the foundation is leveled 9 Route the conduits through the foundation s holes B 10 Fill the space surrounding the foundation in the ground and the channels for the conduits with filling material e g sand Filling material should be packed 2 3 times with a packing machine until the desired ground lev...

Page 45: ...re are two options for mounting the Dual Depot Charge Box onto a wall Utilizing the mounting holes located on the back side of the Box Using external wall mounting brackets see section Wall mounting brackets for Dual Depot Charge Box safe wall fixing on Page 21 1 Drill holes in the wall at the indicated locations A of one of the chosen mounting options see pictures above For a concrete or stone wa...

Page 46: ...ation and may differ between specific locations Due to this reason the installation of those cable ducts is out of scope of this Installation Guide The installation as well as previous preparation of a routing plan of the cable ducts is a responsibility of the Contractor 4 4 Cable routing 4 4 1 Charge system configuration There are various cabling solutions depending on the installation Overview o...

Page 47: ...rnet cable Grounding of the Dual Depot Charge Box on Page 48 This cable can be connected directly from AC distribution to each Dual Depot Charge Box or can be routed in daisy chain mode 4 4 3 Cables connecting the Power Cabinet and the Dual Depot Charge Box 2x DC power cables 0 3x PE cable refer to section Cables connecting the Dual Depot Charge Boxes 1x or 2x AC auxiliary power cable in case dais...

Page 48: ...d PE may be connected from locally available ground connection in the vicinity of the Dual Depot Charge Box PE may be routed from Power Cabinet or distribution board via cable conduits In that scenario each Dual Depot Charge Box should have dedicated PE cable There are two 35 mm2 glands in Dual Depot Charge Box used for guiding PE cables to PE connection points inside the box Daisy chaining of gro...

Page 49: ... stop button EMO to the Dual Depot Charge Box Optional external interface Requirements Beacon light 24VDC Three colors Common 24VDC NPN control Max 300mA per one color Stop button 1x NO Normally Open contact Contacts 1A 24VDC is sufficient control purposes Momentary action Can be equipped with background light 24VDC Emergency stop button EMO l 1x NC Normally closed contact 1x Ext Beacon cable 1x E...

Page 50: ... to 70ºC 40ºC to 80ºC Core identification gn ye Acc to IEC 60446 Data cables Functional description Interlock cable Ethernet S FTP CAT6 Ext Beacon cable Ext Stop button cable Ext EMO cable Number of cores 4 8 4 2 4 Twisted pairs Yes 2 x 2 Yes 4 x 2 No No No Cross section 0 75 2 5 mm2 0 25 0 75 mm2 0 5 0 75 mm2 0 5 0 75 mm2 0 5 0 75 mm2 Min Max external diameter to fit through gland 8 9 mm 5 10 mm ...

Page 51: ...2 All cables must correspond to the VDE CE and EAC Low Voltage Directive and must meet the RoHS compliance The identity and or function of the cable must be marked every 2000 mm of the cable s length and on its both ends 4 5 Internet connection In most cases the integrated 3G modem is used for wireless internet access A customer SIM card is not required If there is no 3G signal available a standar...

Page 52: ...ction phase on the planning diagram C1 Routing the cables on Page 53 C2 Unpacking Power Cabinet on Page 54 C3 Moving the Power Cabinet on Page 56 and Installing the Power Cabinet onto a foundation on Page 59 C4 Connecting AC power cables and PE wires to the Power Cabinet on Page 67 Connecting the Power Cabinet s DC power cables on Page 73 and Connecting the communication cable to the Power Cabinet...

Page 53: ...r the cabinet is placed on the foundation 5 Route the DC power cables through the cable conduit 6 Route the AC auxiliary power PE wire Interlock cable and Ethernet cable if required through the other cable conduit 7 Route the communication Ethernet cable through the extra 40 mm cable conduit 8 For the DC power cables make sure that a cable length of 1000 mm and 1500 mm is available above the surfa...

Page 54: ...the Power Cabinet to its final location is the responsibility of the Contractor Upon request it is possible to order a truck with a crane CAUTION Do not pollute the environment with plastic and cardboard packing Dispose of the package elements according the regional applicable regulations regarding the environment Prerequisites All construction work is completed The product is delivered by a trans...

Page 55: ...the Power Cabinet 1 Remove the packaging material from the Power Cabinet 2 Remove the bag which contains the keys cover caps and mounting material that are attached with tape on one of the lifting eyebolts at the top of the cabinet 3 Keep the bag containing the indispensable parts in a safe place Disconnecting Power Cabinet form the pallet 4 Remove the nuts A at the four corners ...

Page 56: ...h a vacuum cleaner Use a thread tap to make sure that the bolts will go in smoothly DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position Do a voltage check to make sure that the electrical power is disconnected from the system Secure against resetting WARNING Make sure that personnel cannot be crushed or become trapped while moving the Power Ca...

Page 57: ...pment Prerequisites A minimum of two qualified workers are required one person to operate the hoisting equipment the other to guide the Power Cabinet to its location Use M16 swivel eye bolts A or M16 bolts with lifting loops B 1 Insert the bolts A or B into the holes at the opposite corners of the cabinet if not placed upon delivery 2 Tighten the bolts 3 Connect the hoisting equipment C CAUTION Ke...

Page 58: ...guide the Power Cabinet to its location 1 Place wooden slats with a thickness of about 10 to 15 mm and a width equal to the width of the fork of the forklift truck on both forks 2 Move the forks of the forklift truck to the gaps at the rear of the Power Cabinet 3 Move the Power Cabinet to the foundation NOTICE The use of the fork slides is mandatory The distance between the outer side of the forks...

Page 59: ...net bag with parts The Power Cabinet is about 500 mm above its location DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position Do a voltage check to make sure that the electrical power is disconnected from the system Secure against resetting WARNING Make sure that personnel cannot be crushed or become trapped while moving the Power Cabinet Placin...

Page 60: ...ot trap the cables C 3 Make sure that the cabinet is aligned with the tapped holes D Connecting the Power Cabinet with its foundation 4 Insert the M16 bolts A fitted with the washers into the holes in the corners 4x NOTICE A minimum of three M16 bolts are need to applied to securely mount the Power Cabinet onto the foundation In case of placing two Power Cabinets next to each other and 100 mm dist...

Page 61: ...que of 200 Nm Removing swivel eye bolts 6 Remove the swivel eye bolts or lifting loops A 7 Place the cover caps B in the holes 4x 5 5 2 Opening the door of the Power Cabinet Prerequisites The key previously removed from the Power Cabinet bag containing parts Opening the Power Cabinet s door 1 Unlock the handle B 2 Use the handle B to open the door A ...

Page 62: ...quisites Tools spanner size 13 1 Loosen the bolts A 2 Move the sliding plate B of the 2 guidance plates 5 5 4 Routing cables through the guidance plates The method of routing cables through the Power Cabinet s floor 1 Route the cables A through the right guidance plates B 2 Make sure that there is sufficient cable length to reach the connectors at the top of the cabinet ...

Page 63: ...31 NOTICE A minimum length of 3000 mm is required as the cable connectors are located in the middle of the Power Cabinet 5 5 5 Tightening sliding plates of the guidance plates Prerequisites Tools spanner size 13 Securing the cables with the guidance plates 1 Move the sliding plates B 2 Tighten the bolts A ...

Page 64: ...Tools torx screwdriver size 2163TX T30 M5 bolts 8x previously removed from the Power Cabinet bag containing parts Attaching border covers to the Power Cabinet 1 Put the front cover A against the bottom front of the Power Cabinet by aligning the four bolts at the back side of the front cover A with the holes in the bottom front 2 Put the rear cover B against the rear front of the Power Cabinet 3 In...

Page 65: ...rame foundation The supplied front and rear cover on the Power Cabinet are not to be used in this case Prerequisites Tools torx screwdriver size 2163TX T30 Attaching border covers to the Power Cabinet s metal frame foundation 1 Put the front border cover A against the bottom front of the Power Cabinet 2 Put the rear border cover B against the rear front of the Power Cabinet 3 Insert the M5 bolts C...

Page 66: ...Only applicable when the Power Cabinet is placed on a concrete foundation Prerequisites Tools spanner size 19 Attaching cover plate to the concrete foundation 1 Place the front cover plate B on the foundation A 2 Make sure that the front cover plate B is aligned with the tapped holes within the foundation 3 Insert the M12 bolts C into the holes 4x 4 Tighten the bolts ...

Page 67: ...ites Tools cross head screwdriver Removing the protection plate 1 Remove the protection plate A by loosening the screws B 2 Put the protection plate and screws in a safe location as they will be installed back later on Removing protection covers form the connector block 3 Remove the 3 protection covers D from the connector blocks C 4 Put the protection covers in a safe location as they will be ins...

Page 68: ... make a loop in the PE wire so it is longer than the phase wires This loop ensures that the PE wire is not the first wire that is disconnected if the Power Cabinet is moved by a collision 2 Cut the PE wire of the AC power cable to the proper length to reach the PE rail Do not make the wire routing neither too tight nor too loose 3 Strip 20 mm of the insulation from the end of the PE wire 4 Attach ...

Page 69: ...nnected from the system Secure against resetting Method of connecting the AC power cables 1 Cut the wires of the AC power cable to the proper lengths to reach the connectors Do not make the wire routing neither too tight nor too loose 2 Strip 20 mm of the insulation from the ends of the wires B 3 Attach wire end rings A at the end of the wires 4 Remove the nuts and washers C from the bolts M12 of ...

Page 70: ...onnector block 1 Take the 3 protection covers previously removed in Removing the protection covers on Page 67 2 Place the protection covers D back on the connector blocks C Attaching the protection plate 3 Take the protection plate and the screws previously removed in Removing the protection covers on Page 67 4 Place the protection plate A back over the main switch and connector blocks and secure ...

Page 71: ...hod of connecting the lightning protection wire 1 Cut the wire of the lightning protection cable to the proper length to reach the PE rail Do not make the wire routing neither too tight nor too loose 2 Strip 20 mm of the insulation from the end of the wire 3 Attach a wire end ring A to the end of the lightning protection wire B 4 Remove the M12 bolt nut and washers from the PE rail 5 Fit the bolt ...

Page 72: ...ower cable to the proper length to reach the PE rail Do not make the wire routing neither too tight nor too loose 2 Strip 20 mm of the insulation from the end of the PE wire 3 Attach a wire end ring A to the end of the PE wire B 4 Remove the M12 bolt nut and washers from the PE rail 5 Fit the bolt C with toothed washer D the PE wire B and the contact washer E 6 Insert the bolt fitted with the PE w...

Page 73: ...ross head screwdriver DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position Do a voltage check to make sure that the electrical power is disconnected from the system Secure against resetting 5 7 1 Removing the protection cover Removing the protection cover 1 Remove the protection plate A by loosening the screws B 4x 2 Put the protection plate an...

Page 74: ...ight nor too loose 2 Strip the insulation on the required length specified by the lug applied at the end of the wire B 3 Attach cable lug A at the end of the wires 4 Remove the nuts and washers C from the bolts M12 of connector block D and E 5 Insert the DC wire marked by red heat shrink with the nuts and washers onto the bolts of pin 1 of the connector block D 6 Insert the DC wire with the nuts a...

Page 75: ...08 2021 Page 75 of 131 5 7 3 Installing the protection cover Attaching the protection cover 1 Take the protection plate previously removed in Removing the protection cover on Page 73 2 Place the protection plate A back over the DC connector blocks and secure the plate by the screws B 4x ...

Page 76: ...r ferrules crimp pliers DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position Do a voltage check to make sure that the electrical power is disconnected from the system Secure against resetting Route the cable to the terminal blocks Preferred cable route Route the Interlock cable to the terminal block A Refer to the figure for the preferred cable...

Page 77: ...3 Crimp a ferrule onto the ends of the White and Brown wires 4 Ensure that the unused wires green and yellow are secured so that they cannot touch metal parts 5 Loosen the connector screws 6 Insert the wires into the connectors see table below Functional description Connector Wire color Interlock In X8 14 Brown Interlock Out X8 7 White Interlock GND X8 Shield refer to the picture above Shield See ...

Page 78: ...e 78 of 131 5 9 Connecting the communication cable to the Power Cabinet Prerequisites Tools ty raps 5 9 1 Routing the cable to the terminal blocks Preferred cable route Route the communication fiber cable to module D1 B and D2 A Refer to the figure for the preferred cable route inside the cabinet ...

Page 79: ...ent v0 4 Document No TBA Date 11 08 2021 Page 79 of 131 5 9 2 Connecting the Ethernet cable to the Power Cabinet Location of the CAN2ETH board 1 Route the Ethernet communication cable A to the CAN2ETH board B 2 Connect the RJ45 plug to the terminal J1 C ...

Page 80: ...uide Document v0 4 Document No TBA Date 11 08 2021 Page 80 of 131 5 10 Closing the door of the Power Cabinet Closing the Power Cabinet s door Prerequisites The key previously removed from the Power Cabinet 1 Close the door A 2 Lock the handle B ...

Page 81: ... 5 11 2 Removing packaging Prerequisites The installation work must be carried out by at least two people WARNING Make sure that personnel cannot be crushed or become trapped while moving the Dual Depot Charge Box and pedestal out of the box CAUTION Warranty Any damage caused during the process of moving the Power Cabinet to its position is not covered by the warranty 1 Unpack the Dual Depot Charg...

Page 82: ... damage caused to the pedestal during its unpacking 10 Remove all protective foam from the pedestal 5 12 Installing the Dual Depot Charge Box onto a Pedestal 5 12 1 Connecting the Pedestal to the Foundation Prerequisites All packaging material is removed from the Pedestal A minimum of two people is required Tools torx screwdriver size T30 spanner size 19 1 Remove the front cover plate A from the P...

Page 83: ...4 Document No TBA Date 11 08 2021 Page 83 of 131 Removing the pedestal s rear cover plate 5 Carefully position the Pedestal B next to the foundation D 6 Pull the cables E through the opening F Indication of the way the pedestal should be place on the foundation ...

Page 84: ... people one of whom will tilt the pedestal on one of the sides Method of connecting the pedestal to the concrete foundation 8 Make sure that the pedestal s base K is aligned with the mounting holes of the foundation D 9 Insert M12 bolts minimum length of the bolts is 35 mm I fitted with washers J into the holes 6x 10 Tighten the bolts with a tightening torque of 10 Nm ...

Page 85: ...AUTION Warranty Any damage caused during the process of moving the Dual Depot Charge Box to its position is not covered by the warranty CAUTION Do not use a compressor to clean the Dual Depot Charge Box Use a vacuum cleaner Mounting the Dual Depot Charge Box onto the pedestal 1 Carefully place the Dual Depot Charge Box against the Pedestal 2 Make sure that the Dual Depot Charge Box is aligned with...

Page 86: ...he Dual Depot Charge Box A minimum of two people is required Tools spanner size 13 WARNING Make sure that personnel cannot be crushed or become trapped while moving the Dual Depot Charge Box CAUTION Warranty Any damage caused during the process of moving the Dual Depot Charge Box to its position is not covered by the warranty CAUTION Do not use a compressor to clean the Dual Depot Charge Box Use a...

Page 87: ...ly see also section Wall mounting on Page 45 2 Put the wall mounting brackets D 4x against the back side of the Dual Depot Charge Box 3 Insert M6 bolts A washers B and spring washers C into the holes of the back side and into the wall mounting brackets D 4x 4 Tighten the bolts with a tightening torque of 10 15 Nm 5 Drill 4 holes G in the wall with a 12 mm drill following the diagram in section Wal...

Page 88: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 88 of 131 Mounting the Dual Depot Charge Box onto a wall ...

Page 89: ...setting 5 14 1 Gland layout of the Dual Depot Charge Box Gland layout at the Dual Depot Charge Box s bottom Gland Clamping range ØF Cable 00 9 16 mm Spare 01 5 10 mm Interlock Out 02 5 10 mm AC In 03 5 10 mm Interlock In 04 5 10 mm AC Out 05 22 32 mm DC In 06 22 32 mm DC Out 07 22 32 mm DC In 08 22 32 mm DC Out 09 3x7 mm Ext EMO Ext Beacon 1 Ext Stop button 1 10 3x7 mm Ext EMO Ext Beacon 2 Ext Sto...

Page 90: ...ites The key previously removed from the Dual Depot Charge Box Opening the door of the Dual Depot charge Box 1 Unlock the handle B 2 Use the handle B to open the door A 5 14 3 Removing the protection cover Prerequisites Tools cross head screwdriver Unscrewing the protection cover 1 Remove the protection plate A by loosening the four screws and their respective washers B ...

Page 91: ...s They must be unplugged before moving the cover plate 3 Put the protection plate A the screws and the washers B in a safe location as it will be installed back later on Removing the protection cover WARNING It is not allowed to remove the connector plates marked in the picture below nor to loosen their mountings Location of the connector plates ...

Page 92: ...p pliers screwdriver Location of PE connector block X8 1 and the preferred cable route 1 Loosen and remove the cable gland s 11 nut for the PE wire 2 Slide the cable gland s nut over the PE wire 3 Route the PE wire B through gland 11 to the PE connector block X8 1 Refer to the figure above for the preferred cable route through the cable duct inside the cabinet 4 Cut the PE wire to the correct leng...

Page 93: ... pedestal on Page 94 Prerequisites Tools wire cutter wire stripper pliers ferrule crimp pliers screwdriver Location of the PE connector block X8 2 1 Loosen and remove the cable gland s 12 nut for the PE wire 2 Slide the cable gland s nut over the PE wire 3 Route the PE wire B through gland 12 to the PE connector block X8 2 Refer to the figure above for the preferred cable route through the cable d...

Page 94: ...cting PE or lightning protection wire to the pedestal Instructions on preparing the PE wires In case the Dual Depot Charge Box is mounted on a pedestal it is crucial that the pedestal is connected to the Dual Depot Charge Box s PE or lightning protection system with a wire NOTICE For safety it is recommended to make a loop on the PE wire so it is longer than the phase wires This loop ensures that ...

Page 95: ...wer cables on Page 68 or Installing lightning protection optional on Page 93 Do not make the wire routing too tight or too loose 5 Shorten the PE led to the Dual Depot Charge Box to the correct length allowing to reach the GND point I 6 Tighten the nut of the gland to secure the PE wire 7 Strip 11 mm of the insulation from the ends of the PE wire inside the Dual Depot Charge Box 8 Crimp a ferrule ...

Page 96: ... the DC power in and output cables Prerequisites Tools wire cutter wire stripper pliers cable lugs spanner size 17 torque wrench size 17 WARNING It is not allowed to remove the connector plates I in the picture below nor to loosen their mountings Location of the DC power input connectors Instructions on preparing the DC wires ...

Page 97: ...he contact point C 12 Tighten the bolt nut F connections with a tightening torque of 20 Nm 13 Tighten the cable glands nuts to secure the DC power cables Connection of the DC outputs 1 Loosen and remove the cable gland s 06 and 08 nuts for the DC power output cables 2 Slide the cable gland s nuts over the DC power cables 3 Insert the DC power cables into the cable gland 06 and 08 4 Strip the lengt...

Page 98: ... Date 11 08 2021 Page 98 of 131 NOTICE The connections presented below should be executed by leading the required cables through the conduit A located behind the connections bars B Utilize tie wraps to attach the cables to the holders C Location of the cable conduit and holders ...

Page 99: ...side the cabinet 4 Cut the AC auxiliary power cables to the correct length allowing to reach the terminal block X4 Do not make the cable routing too tight or too loose 5 Tighten the nuts of the glands to secure the AC auxiliary power cables 6 Strip 11 mm of the insulation from the ends of the wires B 7 Crimp ferrules A to the ends of the wires B 8 Loosen the connector screws of terminal blocks X4 ...

Page 100: ...terlock cable 3 Route the Interlock cable through gland 03 to the terminal blocks X3 Refer to the figure above for the preferred cable route through the cable duct inside the cabinet 4 Shorten the InterLock cable to the correct length allowing to reach the terminal block X3 Do not make the cable routing too tight or too loose 5 Tighten the nut of the gland to secure the InterLock cable 6 Strip 11 ...

Page 101: ...12 Tighten the connector screws of the terminal blocks with a tightening torque of 1 3 Nm 5 14 10 Connecting the InterLock cable to the next Dual Depot Charge Box Location of terminal blocks X4 and the preferred cable route Positions of terminal blocks X4 required for connection of InterLock 1 Loosen and remove the cable gland s 01 nut for the Interlock cable 2 Slide the cable gland s nut over the...

Page 102: ...n X4 4 White Interlock Out X4 5 Brown DC Guard A X4 8 Green DC Guard A GND X4 9 Yellow Interlock GND X4 1 Shield See also Appendix F Signal connection diagram 5 14 11 Connecting the communication Ethernet cable input Information in this chapter refers to the communication cables connecting the Dual Depot Charge Box to the Power Cabinet or a preceding Dual Depot Charge Box 1 Loosen and remove the c...

Page 103: ...ove the cable gland s 16 nut for the communication Ethernet cable 2 Insert the communication cable into the cable gland 16 and tighten the cable gland s nut to secure the cable s Location of terminal X12 and instructions on the connection 3 Route the Ethernet cable to the terminal X12 refer to the picture above for the preferred cable route Do not make the cable routing too tight or too loose 4 Pl...

Page 104: ... stripper pliers screwdriver ferrules crimp pliers Location of terminal blocks X3 and X4 and the preferred cable route Positions of terminal blocks X3 and X4 required for connection of external devices NOTICE There is a possibility to connect an external Beacon light Stop button and or Emergency Stop Button s EMO to the Dual Depot Charge Box see for more details section Optional external interface...

Page 105: ...r screws 10 The red wire connecting pins X4 28 and X4 29 must be removed if the Ext EMO 1 is applied 11 The black wire connecting pins X4 30 and X4 31 must be removed if the Ext EMO 2 is applied 12 Insert the wires of the cables into the corresponding connectors of the terminal block X4 refer to the table below 13 Tighten the connector screws of the terminal blocks with a tightening torque of 1 3 ...

Page 106: ... External stop button 24 V and X3 15 X4 15 External stop button 0 V provide power supply of 24VDC Their connection is necessary only if the applied button requires additional power supply e g to highlight it with a LED 10 Tighten the connector screws of the terminal blocks with a tightening torque of 1 3 Nm Functional description Connector External stop button CCS 1 X3 10 External stop button CCS ...

Page 107: ...rewdriver Mounting the protection cover Attaching the protection cover with screws 1 Take the protection cover the screws and the washers that were previously removed in Removing the protection cover on Page 73 2 Place the protection cover A back over the DC contactors and secure it with the screws B combined with the washers C 3 Reconnect the plugs of the fans power supply cables ...

Page 108: ...4 Document No TBA Date 11 08 2021 Page 108 of 131 5 14 15 Closing the door of the Dual Depot Charge Box Prerequisites The key previously removed from the Dual Depot Charge Box Closing the door of the Dual Depot Charge Box 1 Close the door A 2 Lock the handle B ...

Page 109: ...09 of 131 5 14 16 Reattaching rear cover plate of the Pedestal Prerequisites Tools torx screwdriver size T30 wire cutter wire stripper pliers cable lugs 2x spanner size 10 torque wrench size 10 Reattaching the pedestal s rear cover plate Overview of the pedestal after reattaching the rear cover plate ...

Page 110: ... to connect the cover plate and the pedestal with a PE wire Prepare a wire of appropriate length no longer than allowing to open the rear cover plate 4 Strip the length of the insulation specified by the size of the wire end rings G at both ends of the wire 5 Attach wire end rings G at the ends of the wire 6 Place the contact washers J the ends of the PE wire L and the toothed washers I onto the G...

Page 111: ... 131 5 14 17 Reattaching front cover plate of the Pedestal Prerequisites Tools torx screwdriver size T30 wire cutter wire stripper pliers cable lugs 2x spanner size 10 torque wrench size 10 Reattaching the pedestal s front cover plate Overview of the front cover plate s connection from inside the pedestal ...

Page 112: ... rear cover plate 2 Strip the length of the insulation specified by the size of the wire end rings G at both ends of the wire 3 Attach wire end rings G at the ends of the wire 4 Place the contact washers J the ends of the PE wire L and the toothed washers I onto the GND points E F 5 Screw the M8 nuts K onto the GND points D E 6 Tighten the nuts with a tightening torque of 15 Nm 7 Place the front c...

Page 113: ...r from the ABB Delivery department and or a certified local ABB service engineer Both will need the support from the local Contractor Before the service engineer can begin the following conditions must be met All installation works are completed Power grid is available A local technician is present for assistance and to switch the power on An electric or hybrid bus available to perform the functio...

Page 114: ...ircumstances ABB will be represented by a project engineer The CAF contains information about the project number location charger type a checklist regarding the delivery the commissioning SAT checklist A list of remaining items Once the CAF is signed the customer support will be handled by the ABB Service department If there are any remaining items they can be listed on the CAF document together w...

Page 115: ...power supply group for the product is set to the OFF position Do a voltage check to make sure that the electrical power is disconnected from the system Secure against resetting 7 2 Cleaning of the cabinet The Power Cabinet and the Dual Depot Charge Box are powder coated The coating must be kept in good condition Clean the Power Cabinet and the Dual Depot Charge Box three times a year in the follow...

Page 116: ... to rain it is sufficient to clean it twice a year CAUTION Do not use high pressure water jets Water may leak into the Power Cabinet If a high pressure water jet has been used make sure that the inside of the Power Cabinet is dry Only use cleaning agents with pH value between 6 and 8 Do not use cleaning agents with abrasive components Do not use abrasive tools ...

Page 117: ... Efficiency 94 and 96 in power spectrum between 20 and 100 of full power Maximum input current 177 A AC Nominal input current 159 A AC Earth Leakage Current Protection AC 300 mA RCD integrated in HVC150 S AC 30 mA RCD integrated in ACS Control Module Short Circuit Capacity 25 kA AC power connection 240 mm2 max AC Input Dual Depot Charge Box Supply voltage 1 phase GND L N Input voltage 230 V AC 10 ...

Page 118: ...30 V AC 10 Input frequency range 47 63 Hz 1 Nominal input current 2 17 A AC Earth Leakage Current protection AC 30 mA DC output Maximum output power 150 kW Output voltage range 150 850 V DC Maximum output current 200 A DC limited by CCS cable 8 3 Mechanical data Mechanical specification of the Power Cabinet Dimensions H x W x D 2092 x 1170 x 770 mm including swivel eye bolts Weight 1340 kg Volume ...

Page 119: ...ditions Indoors dry Environment specification for the Dual Depot Charge Box Ingression protection IP65 excluding charge cable Temperature range Operation 35 ºC to 55 C Temperature range Storage 10 ºC to 70 C Humidity 5 to 95 RH non condensing Altitude 2000 m max Storage conditions Indoors dry CAUTION Warranty Warranty will be considered void if the HVC R 100 150 E Bus Charger is damaged due to bei...

Page 120: ... of the Power Cabinet 121 B Dimensions of the Dual Depot Charge Box 123 C Dimensions of the Power Cabinet s Concrete Foundation 124 D Dimensions of the Power Cabinet s Metal Foundation 126 E Power Cabinet Outline with the Foundation 127 F Signal connection diagram 128 G Ground overview of the system 129 H WEEE disposal 2012 19 EU 130 ...

Page 121: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 121 of 131 A Dimensions of the Power Cabinet ...

Page 122: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 122 of 131 ...

Page 123: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 123 of 131 B Dimensions of the Dual Depot Charge Box ...

Page 124: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 124 of 131 C Dimensions of the Power Cabinet s Concrete Foundation ...

Page 125: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 125 of 131 ...

Page 126: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 126 of 131 D Dimensions of the Power Cabinet s Metal Foundation ...

Page 127: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 127 of 131 E Power Cabinet Outline with the Foundation ...

Page 128: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 128 of 131 F Signal connection diagram ...

Page 129: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 129 of 131 G Ground overview of the system ...

Page 130: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 130 of 131 H WEEE disposal 2012 19 EU ...

Page 131: ...HVC R 100 150 E Bus Charger Installation Guide Document v0 4 Document No TBA Date 11 08 2021 Page 131 of 131 NOTES ...

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