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MANUAL: NORTH AMERICA
Terra DC Wallbox UL
Three-phase Version Installation Manual Rev 2.1
Page 1: ... MANUAL NORTH AMERICA Terra DC Wallbox UL Three phase Version Installation Manual Rev 2 1 ...
Page 2: ...ty in the ABB products described 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 docum...
Page 3: ...ice 15 3 2 3 Conduit for power input wires 15 3 2 4 Specification for power input wires 15 3 2 5 Conduit for ethernet cable 16 3 2 6 Specification for ethernet cable 16 3 3 Terra DC Wallbox placement 16 3 3 1 Charging cable reach 16 3 3 2 Terra DC Wallbox position with respect to parking space 17 3 3 3 Required space for installing and maintaining the Terra DC Wallbox 18 3 3 4 Ventilation and airf...
Page 4: ...on 31 7 Maintenance and Cleaning of the cabinet 32 7 1 Recommended Periodic maintenance 32 7 2 Cleaning of the cabinet 32 8 Technical Data 33 8 1 Electrical data 33 8 2 Mechanical data 34 8 3 Environment 34 8 4 Certifications 34 9 Contact information 35 10 Appendix A Mounting points 36 10 1 Terra DC Wallbox Charger wall mounting 36 11 Appendix B Disposal instruction 37 11 1 Directive on Waste Elec...
Page 5: ...t functioning of the charger Owner The legal owner of the charger OCPP Open Charge Point Protocol Open standard for communication with charge stations PE Protective Earth PPE Personal Protective Equipment Equipment such as safety shoes helmet glasses gloves RCD Residual Current Device Breaks the connection if a residual current is detected RFID Radio Frequency IDentification RFID is a com municati...
Page 6: ...this installation guide carefully and attentively Be sure to follow all instructions when installing the charger ABB is not responsible for any damage caused by not following or incorrectly executing the instructions described in this manual 1 2 Intended document users This document is intended to be used by Customers who have purchased a Terra DC Wallbox or customers in the process of ordering an...
Page 7: ...w Charging cable type ABB order code CCS 1 ABB6AGC076604 CHAdeMO ABB6AGC076601 1 4 Signs The following signs are used on the equipment and in this manual DANGER Hazardous voltage Identifies a hazard that could result in severe injury or death through electrocution WARNING Various Identifies a hazard that could result in severe injury or death ...
Page 8: ...rying out installation or maintenance work Write an emergency plan that instructs people what to do in case of emergency Prepare the site where the charge station will be installed according to the requirements de scribed in this guide Ensure there is sufficient space around the charger to carry out maintenance work Appoint a person responsible for the safe operation of the charge station and for ...
Page 9: ...eeding the unit external dis connect or breaker before performing any installation disassem bly repair or replacement of components Follow appropriate re quirements for safe work practices including but not limited to NFPA 70e 2 Perform a voltage check to ensure electrical power is discon nected from the system 3 Only ABB certified technicians should commission the Terra DC Wallbox 4 When the syst...
Page 10: ... regulations regarding disposal of any non reusable Terra DC Wallbox parts 2 Description of the product 2 1 Overview of the system 2 1 1 Complete overview Example of a complete installation A Power distribution board of the owner B Cables in conduit C Terra DC Wallbox D Parking space for charging E Electric vehicle ...
Page 11: ...FID card reader F AC input connection point for Conduit C DC Charging cable G Air inlet D Air outlet H Standard Holster included I Optional Holster purchased separately Standard charging cable holster supplied with Terra DC wallbox Optional charging cable holster sold separate from Terra DC wallbox ...
Page 12: ...TERRA DC WALLBOX UL 2020 10 05 12 38 2 1 3 Inside view A AC input board D Cable gland for DC output 2x B CPI and IMI boards E Cable gland for AC input C External Fan 2x ...
Page 13: ... It is expected that a cellular availability test is performed prior to construction to ensure there is reasonable signal quality to at least one of the AT T and T Mobile 4G LTE bands 2 1900 MHz 4 1700 2100MHz or 12 700 MHz The signal strength must be greater than 85dbm and should be measured with a cellular network signal meter such as a Squid 4G or Sure Call device Handheld mobile phones are not...
Page 14: ...oper electrical grid configuration The allowable grid configuration is shown in the figure below Electrical grid configuration required for 3 phase Terra DC Wallbox UL variant 3ø 480Y 277V input 3 phase 480Y 277V Terra DC Wallbox Neutral Grounding Electrode Conductor 277V 480V Line 1 Line 2 Line 3 Neutral Ground Line 1 Line 2 Line 3 40A fused switch or circuit breaker ...
Page 15: ...ware ordering details based on Step 1 above 3 Carefully execute a project plan to ensure the correct variant of Terra DC Wallbox is used on the project and that the project site s grid configuration is compatible with the Terra DC Wall box 4 Verify the actual grid configuration the Terra DC Wallbox is installed in matches the described criteria during the Terra DC Wallbox commissioning 3 2 2 Overc...
Page 16: ...eered solution Minimum bandwidth upload 128 kb s download 4 Mb s 99 9 availability 600V rated cable that may route beside input power wires for short distances 3 3 Terra DC Wallbox placement Placement of the Terra DC Wallbox must be carefully determined by accounting for charging cable reach Terra DC Wallbox position with respect to parking space bollards and wheel stops ventilation and working cl...
Page 17: ...ed at different positions depending on the manufacturer The most common vehicles have inlets located either on the front or in the back on either the left or right side This makes some charger placements with respect to the parking space more favorable than others Keep this in mind when designing a site Below are examples of possible situations ...
Page 18: ...f 36 x 48 This space is calculated as follows Charger size H x W x D 30 3 x 23 x 11 8 in Bottom side 23 6 15 75 from the Terra DC Wallbox in order to avoid obstacles for the electrical con nection Left and right side 300mm 12 in order to operate without obstacles on the lateral side of the Terra DC Wallbox Note The below dimensions are shown in millimeters ...
Page 19: ... 5 Considerations for where to position Terra DC Wallbox vertically The below picture shows the height of the operable parts and display screen from the top and bottom of the Terra DC Wallbox s enclosure not accounting for piece on enclosure where the customer con duits connect to It is the installer s responsibility to use this information to define the height at which to install the Terra DC Wal...
Page 20: ...unting on a pedestal The Terra DC Wallbox can also be mounted on a pedestal In order to achieve a safe installation the minimum set of requirements are included in Appendix C Pedestal requirements For the ABB pedes tal solution contact your local ABB sales representative 4 3 Power feed The power cable enters the charger from below Use conduit foam or proper cable lugs and glands to prevent animals...
Page 21: ...box has not been shaken or tilted The cabinet is equipped with Shock Watch and Tilt Watch indicators Checking the Shock Watch and Tilt Watch PLUS sensors If the Shock Watch indicator is red or the Tilt Watch PLUS indicator is tilted over 30 1 Do not refuse the delivery receipt 2 Make a notation on the delivery receipt and inspect cabinet for damage 3 If damage is discovered leave cabinet in origin...
Page 22: ...C Wallbox USE CAUTION TO NOT DAMAGE THE E STOP BUTTON ON THE SIDE OF THE ENCLOSURE 5 Remove the AC ferrite core link to the outlet gun cable assembly position shown at paragraph 5 4 2 6 For all components above remove the shrink wrap 5 2 2 Mounting preparations Unpack the IP BOX and verify all the following items are present Wall frame Frontal cover Bottom grid cover Bottom Cover Grill ...
Page 23: ...to its position is not considered a warranty issue 5 4 Mounting the Terra DC Wallbox Preconditions Tools Spanner Wrench size 17 Guide the power cable through the central cable gland and the Ethernet cable if required through the smaller gland Install the power wiring in the conduit raceway that is connected to the unit See below image for a typical conduit install make ready for installation of th...
Page 24: ... position on the wall bearing by aligning the four holes of the charger with the corresponding holes on the wall bearing 4 Tighten the four screws with stainless steel 8 8 hexagonal bolts 5 Place the unit on the wall frame by correctly aligning the 6 bolts 3 for each lateral side Mounting holes Mounting holes ...
Page 25: ...he lower side of the unit Pay attention to the internal fan power sup ply cable CAUTION DO NOT SET SMALL OBJECTS ON TOP MESH COVER ITEMS MAY FALL INTO THE COOLING FINS OR FAN COMPONENTS 7 Let the auxiliary power supply cable pass through the central gland and tighten it ...
Page 26: ... There are two connectors one for the left fan and one for the right fan 9 AFTER the completing wiring terminations take the bottom cover grill and put it on the lower side of the unit and fix it by tightening two screws as shown in the following picture Please note the 3 phase and 1 phase versions have a slightly different bottom grill assembly ...
Page 27: ...it in place by tighten ing the two screws 11 Center the holes on the plastic cover with the pins on the box 12 Place the central cover on the unit and secure it in place by tightening the two screws located on the left and right side of the cover Center the bottom pins rotate the cover and tighten the 2 lat eral screws ...
Page 28: ...nd to the terminal blocks For the 3 phase version remember to route the wires thru the ferrite Conduit Install shown as a comparison NOTE 1 For 3 phase versions a ferrite core is provided with the Terra DC Wallbox plastic bag within the package or strapped to the CCS 1 cable and needs to be installed in commissioning phase The Ferrite needs to be in serted in the AC in cable and located in the scr...
Page 29: ...er the cabinet 5 5 Connect cables 5 5 1 Connect PE of power cable Preconditions Tools Wire stripper pliers wire end lug pliers wire end lug DANGER Hazardous voltage Make sure that the main switch of the power supply group for the product is set to the OFF position Perform a voltage check and make sure that the electrical power is disconnected from the sys tem Follow recommended NFPA 70e procedures...
Page 30: ...ure the product s power supply group s main switch is set to the OFF position Perform a voltage check and ensure the electrical power is disconnected from the system 7 Cut the 3 phase wires and the neutral wire of the power cable to the correct lengths to reach the connectors 8 Use wire stripper pliers to remove 0 75 in 20 mm of the insulation from the ends of the wires insert and terminate on the...
Page 31: ...move the Terra DC Wallbox after it is commissioned In case the Terra DC Wallbox is moved without ap proval from ABB the warranty will be considered void In case of re location please contact the local ABB Service department Commissioning is executed according to the CSAT checklist this check list can be found in the Helios Suite Service tool that is available to the certified commissioning enginee...
Page 32: ...inet The Terra DC Wallbox Charger is powder coated This coating must be kept in good condition Clean the Terra DC Wallbox Charger three times a year in the following way Remove rough 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 Do a check on the coa...
Page 33: ...output power DC output Maximum DC output power 24 kW peak 22 5 kW continuous DC output voltage range CCS1 150 920 VDC CHAdeMO 150 500 VDC Maximum DC output current 60 ADC 1 Single phase configuration 2 Three phase configuration General DC connection standard EN61851 23 DIN 70121 CCS 2 CHAdeMO 1 0 DC cable length 3 5 meters or 7 meters 12 feet or 23 feet DC plug type CCS 1 CHAdeMO RFID data ISO IEC...
Page 34: ...al data Ingression protection IP54 NEMA 3S indoor and outdoor Temperature range Operation 35 C to 55 C 31 F to 131 F derating applies between 45 C and 55 C 113 F and 131 F Temperature range Storage 40 C to 70 C 40 F to 158 F Humidity 20 95 RH non condensing Operational noise level 55 dBA 25 C Altitude 2500 m max 8 4 Certifications EMC EN 61000 6 4 Class A emission EN 61000 6 3 Class B emission EN ...
Page 35: ...ct information For technical support in North America please visit the ABB E mobility Service Resource Portal For all other regions please contact your local ABB Service organization or Service partner for first line problem analysis and solving ...
Page 36: ...TERRA DC WALLBOX UL 2020 10 05 36 38 10 Appendix A Mounting points 10 1 Terra DC Wallbox Charger wall mounting ...
Page 37: ...TERRA DC WALLBOX UL 2020 10 05 37 38 11 Appendix B Disposal instruction 11 1 Directive on Waste Electrical and Electronic Equipment WEEE 2012 19 EU ...
Page 38: ...Side Back frontal impact MAX applied on the pedestal WB higher point 3kN Pulling Pushing force applied to gun holders if they are me chanically connected to same structure and external to the WB area 3kN Min Max distance of gun holder from WB if mechanically con nected to pedestal structure 300mm 1000mm Rust protection paint Yes Minimum clearance areas side top bottom around the charger 300mm Reco...
