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HVC 450 kW E-Bus Charger Installation Guide

Revision: 1.2

COMPANY CONFIDENTIAL

Date released: 16-08-2018

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Workflow with pre-fabricated concrete foundation

Workflow with metal frame foundation

Workflow with custom foundation (footprint)

Construct foundation of the ABB Pole

Pole foundation constructed on site or mounted on concrete floor

Workflow with pre-fabricated concrete foundation

Charge system configuration

Cables between the Power Cabinets and the ACS Control Module

Cables between the Power Cabinets

Cable specification list

Internet connection

Placement and Connection

About placement and connection

Route the cables

Unpack Power Cabinet

Before unpacking

Remove packaging

Move Power Cabinet to position

Move cabinet with a hoist

Move cabinet with a forklift truck

Install Power Cabinet onto the foundation

Connect Power Cabinet to foundation

Open the door of the Power Cabinet

Move the sliding plate of the guidance plates of the cabinet

Route cables through guidance plates

Move sliding plates of the guidance plates of the cabinet

Install border covers of the Power Cabinet

Install border covers of metal frame foundation

Install front cover plate on foundation

Connect AC power cable and GND wires Power Cabinets

Remove the protection covers

Connect the GND wire of the AC power cable

Connect the AC power cable

Install the protection covers

Install lightning protection (optional)

Connect the GND wire to the ABB Pole

Connect the GND wire between the Power Cabinets

Connect the DC power cables Power Cabinets

Remove the protection covers

Connect the DC power cables

Install the protection covers

Connect AC utility power, Interlock and CAN cables Power Cabinet

Route the cables to the terminal blocks

Connect the AC utility power cable

Connect the Interlock cable

Connect the CAN cable

Connect the communication cable Power Cabinet

Route the cable to the terminal blocks

Connect the communication fiber cables

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Summary of Contents for HVC

Page 1: ... INSTALLATION GUIDE HVC 450 kW E Bus Charger Installation Guide for NA products Version 1 2 Attachment A ...

Page 2: ...bed in this document The information in this document is subject to change without notice and should not be construed as a commitment by ABB ABB assumes no responsibility for any errors 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 f...

Page 3: ...rom m mm to ft Inch Nm to ft lb and kg to lb Changed PE to GND and RCD to GFCI Name Bus bar Box changed in Junction Box Update cable list Description added for own making pole foundation Numbering change of connector X4 in the ACM Handling instructions for connecting the glass fiber cable in ACM adapted 1 0 30 04 2018 First commercial release 1 1 20 07 2018 Height specification HVC 150 adapted Ada...

Page 4: ...n for ABB Pole construction 20 2 2 3 Communication glass fiber cable 21 2 2 4 Electrical components 21 2 3 Project planning 23 3 Preparation 24 3 1 About preparation 24 3 2 Permits 25 3 2 1 Power connection 25 3 2 2 Construction permit 25 3 2 3 Internet access 25 3 3 Upgrade grid 26 3 4 Location 26 3 5 Geometry of infrastructure 27 3 5 1 Required space for the Power Cabinet 27 3 5 2 Placement of m...

Page 5: ... to foundation 57 5 5 2 Open the door of the Power Cabinet 59 5 5 3 Move the sliding plate of the guidance plates of the cabinet 60 5 5 4 Route cables through guidance plates 60 5 5 5 Move sliding plates of the guidance plates of the cabinet 61 5 5 6 Install border covers of the Power Cabinet 62 5 5 7 Install border covers of metal frame foundation 62 5 5 8 Install front cover plate on foundation ...

Page 6: ...x 95 5 16 5 Connect the AC utility power cable from Power Cabinet 97 5 16 6 Connect the communication cable from the Power Cabinet 97 5 16 7 Connect the WiFi cable 99 5 16 8 Connect the RFID cables 99 5 16 9 Connect the other cables to the ACS Control Module 101 5 17 Close the door of the ACS Control Module 102 5 18 Install masks plate work 103 5 19 Grouting of the pole construction 108 6 Commissi...

Page 7: ... 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 OPP Charge Is a trade name of fast charging method for electric vehicles Owner The legal owner of the charger Pantograph The mechanical contact linkage of the charger through which the D...

Page 8: ... this Installation Guide carefully and attentively Follow the instructions in this Installation Guide ABB is not responsible for any damage that has been 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 a HVC 450 kW E Bus Charger or are in the process of ordering...

Page 9: ...ired 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 write an emergency plan that instructs people what to do in case of emergency To prepare the site where the charge station will be installed according to the requirements described in this guide To make sure that ...

Page 10: ...idance on the requirements for safe operation of mobile cranes ML 03 9Akk104941D0113 WARNING Personal safety PPE Always wear a safety helmet safety gloves and safety shoes when you do the lifting and tilting work 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 equ...

Page 11: ...e performing any installation 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 450 kW E Bus Charger 4 When the system is in an open or dangerous condition do not allow unqualified persons to go near it Instruct and warn people about the po...

Page 12: ...o allow service personnel to quickly move away from the ACS Control Module if there is an emergency when the door is open CAUTION Warranty Installation and commissioning work must be carried out by certified personnel The warranty will be void if any work carried out by non certified personnel 1 5 Environment and disposal of waste CAUTION Always observe the local rules and regulations with respect...

Page 13: ...6 Contact information ABB in your country Please contact ABB in your country for sales delivery and service information ABB EV Infrastructure global ABB EV Infrastructure Address Delftweg 65 2289 BA Rijswijk The Netherlands Telephone 31 70 307 62 00 Mail info evci nl abb com Write down here your local ABB contact details ...

Page 14: ...ltiple components and it may require additional parts depending on the project and location of installation which dictates whether these parts are needed ABB offers two standard delivery system configurations 1 Standard HVC 450 kW E Bus Charger with pole 2 Standard HVC 450 kW E Bus Charger without pole Additional needed components can be ordered separately and are not part of the standard delivery...

Page 15: ...system configuration provides the following parts 1x HVC 150 Power Cabinet 2x HVC 150S Power Cabinet 1x Charge control set including 1x ACS Control Module ACM 1x Junction Box 1x Pantograph ACS 1x WiFi communication unit for the bus 1x Charge state indicator light NOTICE The cables between the ACS Control Module and pantograph is not part of the order However the length of the cable will depend on ...

Page 16: ...3 Power Cabinet Outside view of the Power Cabinet A 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 Power Cabinet A Main switch D Data communication connection B AC Power connection E Display only present in HVC 150 C Guidance plate of the cables ...

Page 17: ...2 1 4 ACS Control Module Outside view of the ACS Control Module A Door B Locks C WiFi coax connector D In and outputs for cables from Power Cabinet and to pantograph E In and outputs DC power cables Inside view of the ACS Control Module A Communication connection B Connection block C Protection cover for DC contactors ...

Page 18: ...2 1 5 Junction Box Outside view Junction Box A Cover B In and outputs DC power cables C Output DC OVP sensing cable 2 1 6 ABB Pole Outside view ABB Pole A Door B Emergency button EMO C Charge state indicator light beacon D Distance sensor E Pantograph installation specific F WiFi communication unit G RFID unit optional ...

Page 19: ...F Tension spring G Collector head 2 2 Accessories The following parts can be ordered at the time of the initial order or afterwards Contact ABB Sales department see Contact information on Page 13 for contact details 2 2 1 Foundation for Power Cabinet Pre fabricated concrete foundation The pre fabricated concrete foundation can be used to install the Power Cabinet on soil A Foundation B Top cover p...

Page 20: ...Power Cabinet on a solid surface A Foundation B Front border cover C Rear border cover 2 2 2 Foundation for ABB Pole construction Pre fabricated concrete foundation The pre fabricated concrete foundation can be used to install the ABB Pole construction on soil A Base plate B Counter weights Pulse tube foundation The pulse tube foundation can be used to install the ABB Pole construction on soil ...

Page 21: ...t Part number Description 1 OM3 prefabricated OM3 PCF or fiberglass multimode 850 nm optic cable with 8 fibers 4 for spare with B FCO ST connectors 2 2 4 Electrical components Emergency unit Integrated in the pole but need to be ordered separately if ordered without pole Amount Part number Description 1 1SFA619550R1051 CE4T 10R 02 Emergency stop button 1 1SFA619811R1000 CEP1 0 Enclosure Distance s...

Page 22: ...018 Page 22 of 128 Amount Part number Description 1 RFU 630 13101 RFID RFU63x Sick 1 SSL 2J04 G10ME part 6030928 RFID Ethernet cable 10 m male connector M12 4 pin straight D coded male connector RJ45 8 pin straight Sick 1 2070427 RFID Power cable 10 m female connector M12 17 pin straight A coded Sick ...

Page 23: ...he contractor can do the civil and electrical works See About preparation on Page 24 B Construction The contractor does all civil and electrical works See About construction on Page 35 C Placement and Connection The location is mechanically and electrically ready to receive the HVC 450 kW E Bus Charger See About placement and connection on Page 51 D Commissioning The delivery department will bring...

Page 24: ... site among other things drawings calculations certifications licenses and test reports The location of the HVC 450 kW E Bus Charger must be chosen See section Location on Page 26 and section Geometry of infrastructure on Page 27 A3 Get permits Take care of all permits and local regulations See section Permits on Page 25 A4 Upgrade grid If required upgrade the electrical grid connection to 3 phase...

Page 25: ...ctrical installation on Page 33 3 2 2 Construction permit The installation of the HVC 450 kW E Bus Charger requires the following construction work A solid base Work permit Cable conduits for cables between the power distribution board and the Power Cabinet Usually these cable conduits are installed below ground Cable conduits for cables between the Power Cabinet and ACS Control Module Parking spa...

Page 26: ...the following requirements The height is not more than 6561 68 ft above sea level The HVC 450 kW E Bus Charger must not be immersed in water or any other fluid The operational temperature of the HVC 450 kW E Bus Charger is between 35 and 45 C For locations where the Power Cabinet will be exposed to direct sunlight and high ambient temperatures for most of the day it is recommended to install prote...

Page 27: ... side if another Power Cabinet is placed next to it 3 94 Inch or 0 Inch at the right side if another Power Cabinet is placed next to it 47 24 Inch at the front side in order to open the front door If the cabinet is placed inside a room consider extra 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 wit...

Page 28: ...Maximum allowed pressure drop 300 pA If the pressure drop of the room is higher than 300 pA an extra fan should be placed Contact ABB Sales department see Contact information on Page 13 for contact details 3 5 2 Placement of multiple cabinets There are some possible configurations for the placement of multiple HVC 150 systems see picture below When placing multiple HVC 150 systems it is necessary ...

Page 29: ...ls on the roof of the bus In general the bus has a certain freedom degree to position under the pantograph Drive direction 23 62 11 81 Inch Sideway 19 69 9 84 Inch When the road is horizontal and the top of road TOR is flat no wear NOTICE Before ordering the ABB pole the correct position of the pantograph within the pole must be calculated by ABB This is determined during the site survey for place...

Page 30: ... and doesn t have an angle in the sideway direction of the bus else the minimum and maximum distance need to be re calculated Kneeling of the bus will cause a displacement of the rails on top of the bus of about 7 87 Inch talking 3 5 angle into account with a the height of the bus 129 13 Inch This should also be taken into account when determining the minimum or maximum distance between pole and b...

Page 31: ...ering the ABB pole This will also be noted by ABB during the site survey for the placement of the pole Contact ABB Sales department see Contact information on Page 13 for contact details The hinge point of the pantograph s arms is always located on the same side as the bus driver shown in the figure that follows In this case the pantograph s contact rails make the right electrical contact with the...

Page 32: ... should be taken into account calculating the maximum and minimum distance between the pole and the street curb 3 6 4 Maximum slope of the road in driving direction In drive direction of the bus the lower plain of the contact strips should be parallel to the road See picture below NOTICE The road inclination should be known before the pole can be built This must be communicated with ABB before ord...

Page 33: ...length and method of installation This must be determined by your contractor 3 8 Civil installation DC power cables AC utility power cable GND wire and data cables must be routed between the Power Cabinet and the Charge control set Therefore two flexible cable conduits with an outer diameter of 6 30 Inch must be installed between the foundation of one of the Power Cabinets and the foundation of th...

Page 34: ...in to the earth near the pole foundation It is recommended to place two electrodes near the pole In some cases also additional grounding is required at the Power Cabinet side This is dependent on the local regulations and should be determined by the contractor If the grid is TT based consult the grid owner It is possible that an extra 0 9 Ω electrode is required This requirement must be determined...

Page 35: ...phase are shown in the figure below B1 Civil engineering works Construction of the foundation See section Construct foundation of the Power Cabinet on Page 36 and section Construct foundation of the ABB Pole on Page 41 Installation of the cables See section Cabling on Page 46 Construction of the bus stop surrounding See section Geometry of infrastructure on Page 27 B2 Electrical engineering works ...

Page 36: ... and exit to come to and to go out from the Power Cabinet For detail drawings of the pre fabricated concrete foundation see Appendix E Dimensions concrete foundation Power Cabinet Solid floor 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 19 For detail drawings see Appendix F Dimensions m...

Page 37: ...The conduits must come out of the foundation with a length of about 9 84 Inch 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 0 59 Inch above ground level see figure above 7 Make sure that the top surface of the foundation is leveled 8 Route the conduits thr...

Page 38: ...s required to connect the AC power cable with the connectors in the Power Cabinet without problems 11 Place both cover plates on the appropriate place on 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 ...

Page 39: ... F Dimensions Metal Foundation Power Cabinet on page 123 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 ca...

Page 40: ...ther cables comes 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 3 28 ft is available above the floor for internal routing in the cabinet 6 For the other cables make sure that a cable length of 9 84 ft is available above the floor for internal routing in ...

Page 41: ...wings see Appendix G Dimensions pre fabricated concrete foundation Pole Soil option 2 Use a tube foundation to get a firm fixation on soil This tube foundation can be used if there are space restrictions for example close to a building Contact the ABB Sales department for more information and possibilities see Contact information on Page 13 for contact details Solid floor The local contractor is r...

Page 42: ...sed The time frame in which the soil settlement will be elaborated is depending on Sand compaction during installation Pavement around the construction Wetter conditions rain frost temperature Before starting to install the concrete foundation the pressure of the soil must be measured It is advisable to install the concrete foundation on a soil pressure 100 kPa If the measured soil pressure is mor...

Page 43: ...ing position of the bus The bottom of the concrete base plate must be default 38 11 0 20 Inch under this level This value may differ from the current location so the correct value must be defined by ABB NOTICE Be aware that the correct height to the bottom of the concrete base plate relative to the ground level of the top of road charging position of the bus must be calculated by ABB Contact ABB S...

Page 44: ...180 degrees to face the cable entries to the other side With preparation of the soil the concrete base plate can be installed There are four bullet head anchors 5 85 DH pouring in the concrete base plate Hoist the base plate with using four lifting claws connected with four slings or chains with sufficient capacity The weight of the base plate is 7495 72 lb and the foot print is 94 49 x 94 49 Inch...

Page 45: ...slings or chains with sufficient capacity The weight is 4695 85 lb and the foot print is 94 49 x 37 80 Inch 5 Compaction the soil around the concrete foundation Before filling the gap around the concrete foundation ensure that all Conduits are installed to the concrete base plate The conduits must come out of the holes on the top side of the concrete base plate with a length of about 9 84 Inch Cov...

Page 46: ...ion situation and the cable types used When the cables are routed below ground use cables that are suitable for underground installation The identity and or function must be marked on every 78 74 Inch of the cables and on both ends NOTICE ABB recommends the use of crimped lugs for cable connections to Power Cabinet and Charge Post Mechanical lugs can be used at the discretion of the installer and ...

Page 47: ...or The maximum diameter of the cable conductor is 240 mm2 500 MCM The GND conductor of the power cable must have the same diameter as the phase conductors 4 4 4 Cables between the Power Cabinets and the ACS Control Module The following cables are not in the scope of supply of ABB 6x DC power cables 1x DC OVP Sensing cable between Junction Box and ACM 1x GND cable 1x AC utility power cable 1x Inter...

Page 48: ... installation conditions cable length cable temperature rating losses and local regulations AC and DC power cables Functional description DC Power cable PE cable AC utility power cable Number of cores 1 1 4 Cross section 350 600 MCM 2 AWG 14 AWG Min Max external diameter to fit through gland 1 06 1 38 Inch 0 51 0 83 Inch 0 20 0 39 Inch Shielding No No No Conductor Tinned copper or aluminum conduct...

Page 49: ...VW 1 CSA FT1 All cables must be must meet the UL and the RoHS compliance Cables between ACS Control Module and Pantograph These cables normally integrated within the ABB pole however these cables needed if the charge system is ordered without ABB pole Power cables Functional description DC Power cable PE cable DC OVP Sensing cable Number of cores 1 1 1 Cross section 350 600 MCM 2 AWG 8 AWG Min Max...

Page 50: ...that can be used outdoor and are UV protected PVC or other material that can be used outdoor and are UV protected PVC or other material that can be used outdoor and are UV protected PVC or other material that can be used outdoor and are UV protected Characteristic impedance 50 Ω Frequency range 0 3 GHz 6 GHz Test Voltage 2 kV 2 kV 2 kV 4 kV 2 kV 4 kV 2 kV 4 kV 2 kV 4 kV Nominal Voltage Uo U 600 10...

Page 51: ...Route the cables on Page 52 C2 Unpack on Page 53 C3 Move Power Cabinet to position on Page 54 and Install Power Cabinet onto the foundation on Page 57 C4 Connect the AC power cable on Page 64 Connect the DC power cables on Page 70 Connect AC utility power Interlock and CAN cables Power Cabinet Connect AC utility power Interlock and CAN cables on Page 72 and Connect the communication fiber cables o...

Page 52: ...ICE Step 2 and 3 are only applicable when the Power Cabinet is placed on a concrete foundation The top cover plate is not needed any more after the cabinet is placed on the foundation 4 Route the DC power cables through the 6 30 Inch cable conduit 5 Route the AC utility power GND wire and Interlock cable through the other 6 30 Inch cable conduit 6 Route the communication glass fiber cable through ...

Page 53: ...inet 5 3 1 Before unpacking NOTICE Unloading Power Cabinet The delivery truck only unloads the pallet carrying the Power Cabinet The delivery truck will not move the Power Cabinet to its final location The placement of 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...

Page 54: ... the nuts A at the four corners 5 4 Move Power Cabinet to position There are two options to move the Power Cabinet from the delivery truck to the location Use a hoist to lift the cabinet from the top See Move cabinet with a hoist on Page 55 Use a forklift truck to lift the cabinet from the bottom See Move cabinet with a forklift truck on Page 56 Preconditions All packaging material is removed from...

Page 55: ...on is not covered by the warranty CAUTION Do not use a compressor to clean the Power Cabinet Use a vacuum cleaner 1 Use one of the two options to move the Power Cabinet to the foundation 2 When the Power Cabinet is about 19 69 Inch above its location continue the installation procedure with Install Power Cabinet onto the foundation on Page 57 5 4 1 Move cabinet with a hoist A Swivel eye bolts stan...

Page 56: ...ns A minimum of two persons is required one person to operate the forklift truck the other person to guide the Power Cabinet to its location 1 Place wooden slats with a thickness of about 0 39 to 0 59 Inch 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 next the gaps at the rear of the Power Cabinet 3 Move the Power Cabinet to t...

Page 57: ...rom the Power Cabinet bag with parts The Power Cabinet is about 19 69 Inch 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 WARNING Make sure that personnel cannot be crushed or become trapped while moving the Power Cabinet Placement...

Page 58: ...e sure that you do not trap the cables C 3 Make sure that the cabinet is aligned with the tapped holes D 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 3 94 Inch distance against the wall then...

Page 59: ...Tighten the bolt with a tightening torque of 147 51 ft lb 6 Remove the swivel eye bolts or lifting loops A 7 Place the cover caps B in the holes 4x 5 5 2 Open the door of the Power Cabinet Preconditions Key that were removed from the Power Cabinet bag with parts 1 Unlock the handle B 2 Use the handle B to open the door A ...

Page 60: ... of the guidance plates of the cabinet Preconditions Tools spanner size 13 1 Loosen the bolts A 2 Move the sliding plate B of the 2 guidance plates 5 5 4 Route cables through guidance plates 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 61: ...1 of 128 NOTICE A length of 118 11 Inch is required because the connection of the cables with the connectors in the Power Cabinet is at the middle of the cabinet 5 5 5 Move sliding plates of the guidance plates of the cabinet Preconditions Tools spanner size 13 1 Move the sliding plates B 2 Tighten the bolts A ...

Page 62: ...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 Insert the M6 nut and washer C onto the bolts of the front cover A 4x 3 Tighten the nuts 4 Put the rear cover B against the rear front of the Power Cabinet 5 Insert the M5 bolts D into the holes 4x 6 Tighten the bolts 5 5 7 Install border covers of metal frame foundation...

Page 63: ...er B against the rear front of the Power Cabinet 3 Insert the M5 bolts C into the holes 8x 4 Tighten the bolts 5 5 8 Install front cover plate on foundation NOTICE Only applicable when the Power Cabinet is placed on a concrete foundation Preconditions Tools spanner size 19 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 ...

Page 64: ...and GND wires Power Cabinets 5 6 1 Remove the protection covers Preconditions Tools cross head screwdriver 1 Remove the protection plate A by loosening the screws B 2 Put the protection plate and screws in a safe location as it will be installed again later on 3 Remove the 3 protection covers D from the connector blocks C 4 Put the protection covers in a safe location as it will be installed again...

Page 65: ...t is longer than the phase wires This loop makes sure that the GND wire is not the first wire that is disconnected if the Power Cabinet is moved by a collision 2 Cut the GND wire of the AC power cable to the correct length to reach the GND rail Do not make the wire routing too tight or too loose 3 Strip 0 79 Inch of the insulation from the end of the GND wire 4 Attach a wire end ring A to the end ...

Page 66: ...ure that the electrical power is disconnected from the system 1 Cut the wires of the AC power cable to the correct lengths to reach the connectors Do not make the wire routing too tight or too loose 2 Strip 0 79 Inch 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 connector block D 5 Insert the 3...

Page 67: ... screwdriver 1 Take the 3 protection covers that was removed in Remove the protection covers on Page 64 2 Place the protection covers D back on the connector blocks C 3 Take the protection plate and the screws that were removed in Remove the protection covers on Page 64 4 Place the protection plate A back over the main switch and connector blocks and secure the plate by the screws B ...

Page 68: ...ze 19 torque wrench size 19 1 Cut the wire of the lightning protection cable to the correct length to reach the GND rail Do not make the wire routing too tight or too loose 2 Strip 0 79 Inch 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 GND rail 5 Fit the bolt C with toothed washer ...

Page 69: ...o not make the wire routing too tight or too loose 2 Strip 0 79 Inch of the insulation from the end of the GND wire 3 Attach a wire end ring A to the end of the GND wire B 4 Remove the M12 bolt nut and washers from the GND rail 5 Fit the bolt C with toothed washer D the GND wire B and the contact washer E 6 Insert the bolt fitted with the GND wire into the GND rail 7 Screw from the bottom of the G...

Page 70: ...t nut and washers from the GND rail 5 Fit the bolt C with toothed washer D the GND wire B and the contact washer E 6 Insert the bolt fitted with the GND wire into the GND rail 7 Screw from the bottom of the GND rail a toothed washer D and a nut F on the bolt C 8 Tighten the bolt nut connection with a tightening torque of 22 13 ft lb 5 7 Connect the DC power cables Power Cabinets Preconditions Tool...

Page 71: ...nstalled again later on 5 7 2 Connect the DC power cables 1 Cut the wires of the DC power cable to the correct lengths to reach the connectors Do not make the wire routing too tight or too loose 2 Strip 1 18 Inch of the insulation from the ends of the wires 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 5 Insert the 2 wires B ...

Page 72: ...rs that was removed in Remove the protection covers on Page 71 2 Place the protection covers B back on the connector blocks A 5 8 Connect AC utility power Interlock and CAN cables Power Cabinet Preconditions 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...

Page 73: ...oute inside the cabinet only within the HVC 150 2 Route the Interlock cable s to the terminal block B Refer to the figure for the preferred cable route inside the cabinet 3 Route the CAN cable to the terminal block B Refer to the figure for the preferred cable route inside the cabinet 5 8 2 Connect the AC utility power cable NOTICE The AC utility power cable for the ACS Control Module is only conn...

Page 74: ...Black L2 X341 3 Red L3 X341 4 Blue 6 Tighten the connector screws 5 8 3 Connect the Interlock cable Interlock cable connection in the slave 2 HVC 150S A Terminal block B Interlock cable from to slave 1 HVC 150S 1 Move the cable towards the terminal block A 2 Strip 0 43 Inch of the insulation from the ends of the wires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Inser...

Page 75: ... the insulation from the ends of the wires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Insert the wires into the connectors see table below Functional description Connector Wire number Interlock In master HVC 150 X286 4 2 Interlock Out master HVC 150 X286 6 1 Interlock GND master HVC 150 X286 9 Shield Interlock In slave 2 HVC 150S X286 7 1 Interlock Out slave 2 HVC 1...

Page 76: ...2 Strip 0 43 Inch of the insulation from the ends of the wires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Insert the wires into the connectors see table below Functional description Connector Wire number Interlock In ACM X286 4 2 Interlock Out ACM X286 6 1 Interlock GND ACM X286 9 Shield Interlock Out slave 1 HVC 150S X286 7 1 Interlock In slave 1 HVC 150S X286 8 2 ...

Page 77: ...ve the cable towards the terminal block A 2 Strip 0 43 Inch of the insulation from the ends of the wires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Insert the wires into the connectors see table below Functional description Connector Wire color CAN H Out X286 10 Brown CAN L Out X286 11 White CAN GND X286 12 or Shield Can Out Shield See also Appendix H Signal connect...

Page 78: ...ires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Insert the wires into the connectors see table below Functional description Connector Wire color CAN H In to master HVC 150 X286 1 Brown CAN L In to master HVC 150 X286 2 White CAN GND to master HVC 150 X286 3 or Shield Can In Shield CAN H Out from slave 2 HVC 150S X286 10 Brown CAN L Out from slave 2 HVC 150S X286 11 ...

Page 79: ... towards the terminal block A 2 Strip 0 43 Inch of the insulation from the ends of the wires 3 Crimp a ferrule onto the end of the wire 4 Loosen the connector screws 5 Insert the wires into the connectors see table below Functional description Connector Wire color CAN H In X286 1 Brown CAN L Out X286 2 White CAN GND X286 3 or Shield Can In Shield See also Appendix H Signal connection diagram 6 Tig...

Page 80: ...rol Module are only connected within the master HVC 150 Power Cabinet see for more details section Cabling on Page 46 5 9 1 Route the cable to the terminal blocks Preferred cable route 1 Route the communication fiber cable to module D1 B and D2 A Refer to the figure for the preferred cable route inside the cabinet only within the HVC 150 5 9 2 Connect the communication fiber cables Preconditions T...

Page 81: ...iber cables D onto module D1 B Rx with Td D1 Tx with Rd D1 NOTICE Four fiber cables are not connected Those fiber cables are meant for spare 4 Bind the cables together and secure the loops loosely with a piece of tak ty or ty rap CAUTION Make the loop bend radius of the fiber cables not smaller than 2 52 Inch otherwise the core of the fiber cable may break 5 10 Close the door of the Power Cabinet ...

Page 82: ...arts of the Charge control set The delivery truck will not move the Charge control set to its final location The placement of the Charge control set 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 Depollute these things according the regional applicable ...

Page 83: ...s The Charge control set are unloaded from the delivery truck The bolts of the foundation are free from dust If necessary clean the bolts with a vacuum cleaner or brush The work must be carried out by at least two persons 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 disconnect...

Page 84: ...e foundation 5 13 Install vertical frame onto the foundation Preconditions Tools spanner size 36 torque wrench size 36 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 Installation on concrete foundation ...

Page 85: ...he bolt and nut leaving the galvanized wire surface intact which promotes corrosion resistance 2 Screw the M24 nuts onto the bolts and place on each nut the 0 32 Inch thick washers 16x The default height between the top of the washer and foundation must be 1 97 Inch NOTICE Do not use the 0 12 Inch thick washers supplied with the foundation The nuts need to be leveled relative to the concrete found...

Page 86: ...t be calculated by ABB Contact ABB Sales department see Contact information on Page 13 for contact details 7 Tighten the nuts with a tightening torque of 590 05 ft lb when no copper fat is used and with a tightening torque of 390 91 ft lb when copper fat is used 8 Screw the second M24 nuts on the bolts 16x 9 Tighten the upper nuts 5 14 Install horizontal frame onto the vertical frame Preconditions...

Page 87: ... connection point on the vertical frame 2 Carefully position the horizontal frame before the connection point on the vertical frame 3 Make sure that the horizontal frame is aligned with the tapped holes 4 Mount the horizontal frame onto the vertical frame First make the M24 bolt washer washer nut connection Use 8 pieces bolts of M24 x 50 Class 8 8 A torque of 588 57 ft lb has to be applied ...

Page 88: ...gs from the horizontal frame 6 Remove the four transport pillars from the horizontal frame 7 Fit the bolt B with toothed washer C the GND braided wire A and the contact washer D 8 Insert the bolt fitted with the GND braided wire into connection in the horizontal frame 9 Tighten the bolt 10 Remove the packing foil from the cables and enroll the cables through the vertical frame 11 Route the cables ...

Page 89: ...isconnected from the system 5 15 1 Connect the GND wire of the ACS GND 1 Cut the GND wire to the correct length to reach the GND rail Do not make the wire routing too tight or too loose 2 Strip 0 79 Inch of the insulation from the end of the wire 3 Attach a wire end ring A to the end of the GND wire B 4 Remove the M8 bolt and washers from the GND rail 5 Fit the bolt C with toothed washer D the GND...

Page 90: ...ten the bolt with a tightening torque of 11 06 ft lb 5 15 3 Connect the GND wire from the Junction Box 1 Cut the GND wire to the correct length to reach the GND rail Do not make the wire routing too tight or too loose 2 Strip 0 79 Inch of the insulation from the end of the wire 3 Attach a wire end ring A to the end of the GND wire B 4 Remove the M8 bolt and washers from the GND rail 5 Fit the bolt...

Page 91: ...ake the wire routing too tight or too loose NOTICE The pole has two lighting protection connections on each side of the vertical frame This make it possible to connect two electrodes when this is required 2 Strip 0 79 Inch of the insulation from the end of the wire 3 Attach a wire end ring A to the end of the lighting protection wire B 4 Remove the M8 bolt and washers from the lighting protection ...

Page 92: ... EMO switch 7 M16x1 5 Beacon 8 M16x1 5 Distance sensor 9 M16x1 5 Temperature sensor 10 M25x1 5 RFID Power cable 11 M32x1 5 Communication fibers 12 M32x1 5 ACS Control 13 M32x1 5 GND 14 M50x1 5 DC In from HVC 150 master 15 M50x1 5 DC In from HVC 150S slave 1 16 M50x1 5 DC Out to pantograph 17 M50x1 5 DC Out to pantograph 18 M50x1 5 DC In from HVC 150S slave 2 19 M50x1 5 Not used 20 M50x1 5 DC Out t...

Page 93: ...ner size13 and 18 torque wrench size 13 and 18 NOTICE Ensure that the DC cables during mounting do not hit the PCBAs on the door of the ACS Control Module When these cables hit the PCBAs the PBCAs can be damaged It is advised to protect the PCBAs during mounting of the DC cables To prevent damage of the PCBAs in the ACS Control Module 1 Cut the DC cables at 15 75 Inch from the bottom side of the A...

Page 94: ...n Gland layout of the ACS Control Module on Page 92 8 Attach cable lug A at the end of the wires 9 Remove the nuts and washers C from the bolts of the DC contactor connectors 10 If present remove the sense wires from the bolts of the DC contactor connectors 11 Insert the wires B onto the correct bolts of the DC contactor connectors see picture above for the correct connection 12 Insert the sense w...

Page 95: ...iers wire end rings Cembre A48 M12 cable lug when using 500 MCM cables 6x spanner size18 torque wrench size 18 cross head screwdriver 1 Loosen the screws C 6x of the Junction Box A 2 Remove the cover B from the Junction Box A 3 Loosen and remove the cable gland s 03 08 nuts for the DC power cables 4 Slide the cable gland s nuts over the DC power cables 5 Strip 1 18 Inch of the insulation from the ...

Page 96: ...6x 12 Secure the bolt E onto the bus bar G with the spring washer H and the nut I 6x 13 Tighten the bolts E and nuts I with a tightening torque of 59 01 ft lb 14 Tighten the cable gland s nut to secure the DC power cables 15 Place the cover B back onto the Junction Box A WARNING If the GND braided wire between the cover and cabinet is disconnected during the installation of the DC power cables mak...

Page 97: ...able 5 Strip the insulation from the AC utility power cable A 6 Cut the wires of the AC utility power cable A to the correct lengths to reach the connectors Make sure the GND wire is longer than the other wires 7 Strip 0 43 Inch of the insulation from the ends of the wires 8 Crimp a ferrule onto the end of the wire 9 Loosen the connector screws 10 Insert the GND wire green yellow into the one of t...

Page 98: ... fiber communication cable always slide the cable gland s rubber seal over the metal finish tulle before insert the glass fiber communication cable into the cable gland 5 Insert the communication cable into the cable gland 11 and tighten the cable gland s nut to secure the cable 6 Route the communication fiber cables to module U5 A and U7 B 7 Remove the protection covers from the optical connector...

Page 99: ...se the core of the fiber cable may break 5 16 7 Connect the WiFi cable 1 Route the WiFi cable A to the WiFi connector B 2 Insert the WiFi type N plug into the WiFi connector B 3 Hand tighten the WiFi plug 5 16 8 Connect the RFID cables NOTICE This section is not required if the RFID module is not present Preconditions Tools wire cutter wire stripper pliers screwdriver ferrules crimp pliers 1 Loose...

Page 100: ...ent cable length do not make the cable routing too tight or too loose 7 Tighten the nut of the gland to secure the RFID Power cable 8 Strip the insulation from the cable 9 Strip 0 43 Inch of the insulation from the ends of only the Brown and Blue wire 10 Crimp a ferrule onto the end of the Brown and Blue wire 11 Cut the other wires except the Brown and Blue wire at the end of the striped insulatio...

Page 101: ...e connector blocks X2 X3 and X4 with sufficient cable length do not make the cable routing too tight or too loose 4 Tighten the nuts of the glands to secure the cables 5 Strip the insulation from the cables 6 Cut the wires of the cables to the correct lengths to reach the connectors 7 Strip 0 43 Inch of the insulation from the ends of the wires 8 Crimp a ferrule onto the end of the wire 9 Loosen t...

Page 102: ... 7 ACS Magn Supply Out 10 Wire 8 ACS GND_B 11 Wire 9 ACS Extended In X4 EMO cable 13 Wire 1 EMO S1 15 Wire 2 EMO S1 14 Wire 3 EMO S2 16 Wire 4 EMO S2 X4 Beacon cable 17 Wire 1 Beacon RD 18 Wire 2 Beacon GN 19 Wire 3 Beacon BU 20 Wire 4 Beacon 24V X4 Distance sensor cable 21 Wire 1 Distance Sensor 24V 23 Wire 2 Distance Sensor NO NC 22 Wire 3 Distance Sensor GND 24 Wire 4 Distance Sensor Analog out...

Page 103: ...ly 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 WARNING Make sure that personnel cannot be crushed or get stuck while moving the parts of the Charge control set WARNING Make sure that personnel cannot be falling from the platform when working at height CAUTION Warranty Damage due to moving the Charge cont...

Page 104: ... Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 104 of 128 4 Mount on the predrilled holes on both sides of the vertical frame A one socket bolt M6x16 including with washer B 5 Hang the backside below cover A on the two bolts B ...

Page 105: ...105 of 128 6 Mount the rest of the fasteners A in the following order lock washer M6 flat washer M6 and bolt M6x16 6x 7 Repeat step 4 5 and 6 for the backside up cover A and front side up cover B 8 Mount on both side on the vertical frame the below U profiles A and then mount on both side the up U profiles B ...

Page 106: ...28 9 Mount the cover door A on the four hinges mounted on the left side of the vertical frame B Place the hinge pins C into the hinges to secure the door Check if the door can be closed and locked Adjust the door suspension if necessary 10 Repeat step 4 5 and 6 for the top back up cover A and the top front up cover B ...

Page 107: ... 128 11 Mount cover A under the horizontal frame Pull them as far as possible to the front 12 Repeat step 4 5 and 6 for the top back under cover A and the top front under cover B 13 Mount on both side on the horizontal frame the back side U profiles A and the front side U profiles B and mount the front U profile C ...

Page 108: ...me and the concrete foundation has to be filled with non shrink grout 1 Place a mold around the foot print of the vertical frame The border collar suggested in Workflow with pre fabricated concrete foundation on Page 42 can be used as mold Make sure the mold is sealed watertight 2 Prepare the grouting mortar NOTICE Read and follow the instruction manual of the used grouting mortar 3 Pour the morta...

Page 109: ...rtified local ABB service engineer Both will need the support from the local contractor Before the service engineer can start the following conditions must be met All installation work is done Grid power is available A local technician is present for assistance and to switch the power on Boom lift available to check all the connections on the pantograph An electric or hybrid bus available to perfo...

Page 110: ...ain circumstances ABB will be represented by a project engineer The CAF contains information about the project number location charger type a checklist about the delivery the commissioning SAT checklist list of remaining items After the CAF has been signed the customer support will be handled by the ABB Service department If there are any remaining items they can be noted on the CAF document toget...

Page 111: ... dirt by spraying with low pressure tap water Apply a neutral or weak alkaline cleaning solution and let it soak Remove dirt by hand with a non woven nylon hand pad Rinse thoroughly with tap water Optionally apply wax on the front for extra protection and gloss Do a check on the coating for damage NOTICE When the HVC 450 kW E Bus Charger is exposed to rain it is sufficient to clean it twice a year...

Page 112: ...cation Power Cabinet Dimensions H x W x D 82 36 x 46 06 x 30 32 Inch Including swivel eye bolts Weight 2954 19 lb Volume 114114 40 in3 Dimensions including packaging H x W x D 88 58 x 47 24 x 31 50 Inch Weight including packing 3086 47 lb Weight concrete foundation 2866 00 lb Mechanical impact protection IK10 Housing Stainless steel 430 Mechanical specification ACS Control Module Dimensions H x W ...

Page 113: ...45 C Temperature range Storage 10 ºC to 70 C Humidity 5 to 95 RH non condensing Altitude 6561 68 ft max Storage conditions Indoors dry Environment specification ABB Pole Ingression protection IP54 Temperature range Operation 35 ºC to 45 C Temperature range Storage 10 ºC to 70 C Humidity 5 to 95 RH non condensing Altitude 6561 68 ft max Maximum operational wind speed 44 7 mph 8 Bft Maximum deflecti...

Page 114: ...5 B Dimensions ACS Control Module 117 C Dimensions Junction Box 118 D Dimensions ABB Pole 119 E Dimensions Concrete Foundation Power Cabinet 121 F Dimensions Metal Foundation Power Cabinet 123 G Dimensions pre fabricated Concrete Foundation Pole 124 H Power Cabinet Outline with Foundation 125 I Signal connection diagram 126 J Ground overview of the system 127 ...

Page 115: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 115 of 128 A Dimensions Power Cabinet All sizes in mm 1 mm 0 039 Inch ...

Page 116: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 116 of 128 All sizes in mm 1 mm 0 039 Inch ...

Page 117: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 117 of 128 B Dimensions ACS Control Module All sizes in mm 1 mm 0 039 Inch ...

Page 118: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 118 of 128 C Dimensions Junction Box All sizes in mm 1 mm 0 039 Inch ...

Page 119: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 119 of 128 D Dimensions ABB Pole All sizes in mm 1 mm 0 039 Inch ...

Page 120: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 120 of 128 All sizes in mm 1 mm 0 039 Inch ...

Page 121: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 121 of 128 E Dimensions Concrete Foundation Power Cabinet All sizes in mm 1 mm 0 039 Inch ...

Page 122: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 122 of 128 All sizes in mm 1 mm 0 039 Inch ...

Page 123: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 123 of 128 F Dimensions Metal Foundation Power Cabinet All sizes in mm 1 mm 0 039 Inch ...

Page 124: ...VC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 124 of 128 G Dimensions pre fabricated Concrete Foundation Pole All sizes in mm 1 mm 0 039 Inch ...

Page 125: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 125 of 128 H Power Cabinet Outline with Foundation ...

Page 126: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 126 of 128 I Signal connection diagram ...

Page 127: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 127 of 128 J Ground overview of the system ...

Page 128: ...HVC 450 kW E Bus Charger Installation Guide Revision 1 2 COMPANY CONFIDENTIAL Date released 16 08 2018 Page 128 of 128 NOTES ...

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