ABB Terra HP Generation 3 UL Installation Manual Download Page 5

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6.3.4

Install the cable gland plates................................................................................43

Electrical installation of the power cabinet.................................. 44

General procedure...................................................................................................................44

7.2

Connect the PE cables to the power cabinet.....................................................................44

7.3

Connect the AC input cables.................................................................................................45

7.4

Connect the DC power cables...............................................................................................46

7.5

Connect the AC auxiliary power cable in the primary power cabinet........................... 47

7.6

Connect the interlock and DC guard cables to the power cabinet............................... 48

7.7

Connect the optical CAN cable between the power cabinet and the charge post.... 49

Electrical installation of the charge post.......................................50

8.1

General procedure...................................................................................................................50

8.2

Connect the PE wires..............................................................................................................50

8.3

Connect the DC power input cables.....................................................................................51

8.4

Connect the AC auxiliary power cable................................................................................. 52

8.5

Connect the interlock and DC guard cable.........................................................................53

8.6

Connect the optical CAN cable............................................................................................. 54

8.7

Connect the Ethernet cable...................................................................................................55

Prepare for commissioning..............................................................57

Access to parts.................................................................................. 58

10.1

Open the door of the power cabinet...................................................................................58

10.2

Remove the plinth covers of the power cabinet............................................................... 58

10.3

Remove the DC busbar cover................................................................................................59

10.4

Remove the AC covers............................................................................................................ 59

10.5

Close the door of the power cabinet.................................................................................. 60

10.6

Open the door of the charge post........................................................................................61

10.7

Remove the plinth covers of the charge post.................................................................... 61

10.8

Remove the protection plate of the charge post..............................................................62

10.9

Close the door of the charge post....................................................................................... 62

Generic procedures...........................................................................64

11.1

Install a cable lug on a wire................................................................................................... 64

11.2

Install a ferrule on a wire........................................................................................................64

11.3

Install insulating heatshrink tubing on a wire................................................................... 65

11.4

Connect a wire that has a cable lug.....................................................................................66

11.5

Connect a wire that has a ferrule......................................................................................... 66

Contents

9AKK107992A3069-EN | 004

Summary of Contents for Terra HP Generation 3 UL

Page 2: ...Copyright All rights to copyrights registered trademarks and trademarks reside with their respective owners Copyright ABB EV Infrastructure All rights reserved 2 9AKK107992A3069 EN 004 ...

Page 3: ... General safety instructions 14 2 3 Required qualifications for the installation person 14 2 4 Personal protective equipment 15 2 5 Safety instructions during transport 15 2 6 Safety instructions during installation 15 2 7 Safety instructions for earthing 16 2 8 Signs on the EVSE 16 2 9 Discard the EVSE or parts of the EVSE 17 2 10 Cyber security 17 3 Description 19 3 1 Intended use 19 3 2 Type pl...

Page 4: ...nspect the EVSE on delivery 33 5 3 Do a check on the transport sensors 33 5 4 Unpack the EVSE 33 5 5 Remove the cabinet from the pallet 34 5 6 Transport the EVSE on the site 34 5 6 1 General transport procedure 34 5 6 2 Tilt the charge post to the vertical position 35 5 6 3 Move the cabinet with a forklift truck 36 5 6 4 Hoist the cabinet 36 6 Installation 38 6 1 General installation procedure 38 ...

Page 5: ... 52 8 5 Connect the interlock and DC guard cable 53 8 6 Connect the optical CAN cable 54 8 7 Connect the Ethernet cable 55 9 Prepare for commissioning 57 10 Access to parts 58 10 1 Open the door of the power cabinet 58 10 2 Remove the plinth covers of the power cabinet 58 10 3 Remove the DC busbar cover 59 10 4 Remove the AC covers 59 10 5 Close the door of the power cabinet 60 10 6 Open the door ...

Page 6: ... Height of user operable elements 76 12 16 Space requirements 77 12 16 1 Power cabinet 77 12 16 2 Charge post 78 12 16 3 Charge post exceptions for bollards and other minor fixed obstacles 79 12 16 4 Distance requirements between power cabinet and charge post 80 12 17 Foundation specifications 80 12 17 1 Power cabinet prefab concrete 80 12 17 2 Power cabinet metal frame 84 12 17 3 Gland plates for...

Page 7: ...12 19 6 Optical CAN cables between the power cabinet and the charge post 97 12 19 7 Ethernet cable 97 12 20 Expected wye input 98 12 21 Electrical connection diagram 99 Contents 9AKK107992A3069 EN 004 7 ...

Page 8: ...ment are in English EN US All other language versions are translations of the original instructions 1 5 Illustrations It is not always possible to show the configuration of your EVSE The illustrations in this document show a typical setup They are for instruction and description only 1 6 Units of measurement SI units of measurement metric system are used If necessary the document shows other units...

Page 9: ...ou do not obey the instruction this can cause damage to the EVSE or to property Note A note gives more data to make it easier to do the steps for example Information about the condition of the EVSE before you start the procedure Requirements for personnel for a proce dure General safety instructions for a proce dure Information about spare parts that are necessary for a procedure Information about...

Page 10: ...e General risk Hazardous voltage that gives risk of electrocution Risk of pinching or crushing of body parts Rotating parts that can cause a risk of entrapment Hot surface that gives risk of burn injuries Note It is possible that not all symbols are present in this document 1 11 Related documents Document name Target group Product data sheet All target groups Installation manual Qualified installa...

Page 11: ...13 Abbreviations Abbreviation Definition AC Alternating current BESS Battery energy storage system CAN Controller area network CPU Central processing unit DC Direct current EMC Electromagnetic compatibility EV Electric vehicle EVSE Electric vehicle supply equipment MID Measuring Instruments Directive NFC Near field communication NoBo Notified body OCPP Open charge point protocol PE Protective eart...

Page 12: ...ractor Third party that the owner or site operator hires to do engineering civil and electrical installation work Grid provider Company that is responsible for the transport and dis tribution of electricity Local rules All rules that apply to the EVSE during the entire lifecy cle of the EVSE The local rules also include the national laws and regulations Open charge point proto col Open standard fo...

Page 13: ... C A Front side face forward to the EVSE during normal use B Left side C Right side D Rear side X X direction positive is to the right Y Y direction positive is rearward Z Z direction positive is upward About this document 9AKK107992A3069 EN 004 13 ...

Page 14: ...nd the instructions in this manual If the local rules contradict the instructions in this manual the local rules will apply If and to the extent permitted by law in case of inconsistency or contradiction between any requirements or procedure contained in this document and any such local rules obey the stricter between the requirements and procedures specified in this document and the local rules 2...

Page 15: ...y the safety instructions that apply to the hoisting equipment or the forklift truck Put on the correct personal protective equipment Refer to section 2 4 2 6 Safety instructions during installation Preliminary requirements 1 Installation engineer Make sure that there is no voltage on the AC input cables during the complete installation procedure Keep unqualified personnel at a safe distance durin...

Page 16: ...onal protective equipment Refer to section 2 4 2 7 Safety instructions for earthing Preliminary requirements Make sure that the EVSE is connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the product Make sure that the connections to the EVSE comply with all ap...

Page 17: ...SE with your household waste at the end of use Instead hand the EVSE over to your local community waste collection point for recycling For more information contact the Government Waste Disposal department in your country 2 10 Cyber security Note This topic is valid for a wired Ethernet connection This product is designed to be connected to and to communicate information and data via a network inte...

Page 18: ...its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage and or theft of data or information Safety 18 9AKK107992A3069 EN 004 ...

Page 19: ...late XX XXXXXX XX SAP PN XXXXXXXXXXXX GLOBAL ID XXXXXXXXXX SN XXXX XXX XXXX XXX FOR USE WITH ELECTRICAL VEHICLES XXXX xxx xxxV MAX XXXA XXXXX xxx xxxV XW PE XXXXX XXXX xxx xxxV XXXXX XXXX xxx xxxV XXX x xkW xxHz XXXX xxxA XXXX xxxA XXXX XX xxV xA ABB B V George Hintzenweg 81 3068 AX Rotterdam The Nederlands MADE IN ITALY Contains FCC ID see note A XXXXXXXXX XXXXXXX Prod date xx xxxx Weight XXX Kg ...

Page 20: ...e post An arrangement can have one or more power cabinets and one or more charge posts For the specifications of the configuration in this manual refer to section 3 4 3 4 Working principle Note For a detailed overview of all electrical connections refer to section 12 21 B D A CU CCB E C CCB F IMI CPI A Distribution board B Power cabinet C Charge post D Surge protection device E Power module x3 F E...

Page 21: ...connections DC power connections Control lines general 3 5 Overview and functions 3 5 1 Power cabinet outside E F D B A C A Plinth cover B Air outlet C Type plate D Door E Air inlet 4x F Enclosure Description 9AKK107992A3069 EN 004 21 ...

Page 22: ...usbar To connect PE cables AC power connector To connect to the AC input power cable Fuse block To protect the machine from overcorrect and pre vent a short circuit of downstream components X 10 terminal block To connect to the AC auxiliary power cable X 8 terminal block To connect the interlock and DC guard cable CAN2FIBER device To connect the optical CAN cable Relays To control the power sharin...

Page 23: ...ration 3 outside C D E F G B A J M L I J K H N A EV charge cable B RFID reader and the payment terminal option C Connector holder D Touchscreen E Door F Top light G Side LED strips H Cable retraction system I Enclosure J Air inlet and outlet K Type plate L Antenna M Hoisting points N Plinth cover Description 9AKK107992A3069 EN 004 23 ...

Page 24: ...ature of the charge cables DC power busbars To connect the DC power cables Cable gland plates Glands for the cables to the charge post PE busbar To connect the PE wire Q1 RCD Residual current circuit breaker to connect or discon nect the AC auxiliary power to the charge post X 10 terminal block To connect the AC auxiliary power cable X 20 terminal block To connect the interlock and DC guard cable ...

Page 25: ... B C D E F G H I J K L A PE wire B AC auxiliary power cable C PE wire D PE wire E CAN cable SAE J1939 11 F Not used G Interlock and DC guard cable H Ethernet cable I DC in cable J DC in cable K DC in cable L DC in cable Description 9AKK107992A3069 EN 004 25 ...

Page 26: ... that the design of the site complies with these specifications The charge cables can get to the inlet for the charge cables on the EVs For the length and cable reach of the charge cables refer to section 12 15 2 The maximum distance between power cabinets Refer to section 12 16 4 The maximum distance between the power cabinet and the charge post Refer to section 12 16 4 The network signal quality...

Page 27: ...d Think of snow or objects 4 4 Prepare the foundation 4 4 1 Prepare the foundation general procedure Caution Make sure that the foundation of the charge post is level You cannot use shims to level the charge post 1 Select the correct foundations based on the underground 2 Prepare the foundation for the power cabinet Type Procedure Prefab concrete foundation Refer to section 4 4 2 Metal foundation ...

Page 28: ...l the foundation with gravel or another substance to prevent rodents to enter the cabinet 4 4 3 Prepare a metal foundation for the power cabinet Preliminary requirements Drill with screw tap Torque wrench Metal frame Refer to section 12 17 2 If you have not included the foundation in the initial order contact the manufacturer to order the foundation for your power cabinet Refer to section 1 12 A m...

Page 29: ... 6 Install the fasteners E 7 Tighten the fasteners to the correct torque For the specification refer to section 12 14 4 4 4 Prepare a custom foundation for the power cabinet Preliminary requirements Custom foundation Refer to section 12 17 4 Procedure 1 Make the custom foundation Caution Make sure that the top surface of the foundation is above the ground level to prevent intrusion of water 2 Guid...

Page 30: ...nto the holes of the foundations Holes A exit cable conduit for the DC power cables Holes B entrance cable conduit for the CAN interlock and DC guard cables from the power cabinet Holes C entrance cable conduit for the AC auxiliary power and PE cables from the power cabinet Holes D entrance cable conduit for the DC power cables Holes E exit cable conduit for the CAN interlock and DC guard cables H...

Page 31: ...e ground For the specifications refer to section 12 16 2 2 Drill and thread the holes Do not make holes in not authorized locations This may compromise the structural integrity of the metal foundation 3 Drill the gland plate to allow the cable conduits to pass through For an overview of the cable conduits refer to section 12 18 For the gland plates refer to section 12 17 7 You can insert your own ...

Page 32: ... foundations For the relation between the cables and the holes refer to section 12 17 8 3 Install the foundation in the hole 4 Put the cables through the openings in the foundation Apply the full cable slack For the cable slack refer to section 12 15 2 5 Fill the foundation with gravel or another substance to prevent rodents to enter the cabinet C1 C3 C4 C2 Pre installation 32 9AKK107992A3069 EN 0...

Page 33: ... sensors 1 Do a check on the sensors A that record the shocks during transport 2 Do a check on the sensors B that record the maximum tilt during transport 3 If the sensors A show a red indication or the sensors B show a tilt that is too high do these steps a Refuse the delivery of the EVSE b Make a note on the delivery receipt c Within three days of the delivery ask the transport company for an in...

Page 34: ...5 6 Transport the EVSE on the site 5 6 1 General transport procedure Preliminary requirements 1 The cabinets are unpacked Refer to section 5 4 Note The charge post is delivered horizontally or vertically Caution Do not tilt the power cabinet to the horizontal position In the horizontal position the power cabinet breaks A Inspection and transport 34 9AKK107992A3069 EN 004 ...

Page 35: ... Refer to section 5 4 Hoisting equipment including cables swivel eye bolts or bolts with lifting loops Refer to section 12 3 Warning Risk of pinching or crushing the charge post is heavy Make sure that the hoisting equipment can lift the charge post safely Obey the safety instructions that apply to the hoisting equipment Take into account the dimensions the mass and the center of gravity of the ch...

Page 36: ...e 1 Move the forks A of the forklift truck in the gaps at the side of the cabinet 2 Move the cabinet to the correct location 5 6 4 Hoist the cabinet Preliminary requirements 1 The cabinet is unpacked Refer to section 5 4 Hoisting equipment including cables not chains swivel eye bolts or bolts with lifting loops Refer to section 12 3 Warning Risk of pinching or crushing the cabinet is heavy Make su...

Page 37: ...cedure 1 Install the swivel eye bolts or bolts with lifting loops A 2 Connect the cables B of the hoisting equipment to the swivel eye bolts or bolts with lifting loops 3 Move the cabinet to the correct location 4 Remove the swivel eye bolts or bolts with lifting loops A 5 Install the plastic cover on the threaded location A B Inspection and transport 9AKK107992A3069 EN 004 37 ...

Page 38: ...arge post Refer to section 8 5 Prepare for commissioning Refer to section 9 6 2 Mechanical installation of the power cabinet 6 2 1 Install the power cabinet general procedure Preliminary requirements 1 The cabinet is above the foundation Procedure 1 Remove the plinth covers of the power cabinet Refer to section 10 2 2 Install the cabinet on the foundation Refer to section 6 2 2 3 Open the cable in...

Page 39: ... sure that there is no kink in the cables 2 Make sure that the holes in the cabinet A and the foundation B are aligned 3 Install the fasteners C and the washers 4 Tighten the fasteners to the correct torque For the specification refer to section 12 14 6 2 3 Open the cable inlets Preliminary requirements Open spanner Procedure 1 Open the door Refer to section 10 1 2 Loosen the fasteners A 3 Move th...

Page 40: ... 2 Guide the DC output cables C through the opening D 6 2 5 Close the cable inlets 1 Move the sliding plates B on the guidance plate to close the cable inlets and hold the cables C in place 2 Tighten the fasteners A 6 2 6 Install the front cover plate concrete foundation Preliminary requirements 1 The cabinet is installed on the foundation Four fasteners M10 Torque wrench C D A B A C B Installatio...

Page 41: ... 48 fasteners M6 included in the foundation kit Four fasteners M12 included in the foundation kit Procedure 1 Install the cover plates A 2 Install the fasteners B and C Include washers 3 Tighten the fasteners to the correct torque For the specification refer to section 12 14 6 3 Mechanical installation of the charge post 6 3 1 Install the charge post general procedure Preliminary requirements 1 Th...

Page 42: ...the cable glands Apply the full cable slack Refer to section 12 15 2 4 Install the charge post on the foundation Refer to section 6 3 3 5 Install the cable gland plates Refer to section 6 3 4 6 Close the charge post a Install the protection plate of the charge post b Close and lock the door of the charge post c Install the plinth covers of the charge post 7 Replace the eye bolts on the charge post...

Page 43: ...es 2 Make sure that the holes in the charge post A and the foundation B are aligned 3 Install the fasteners C and the washers 4 Tighten the fasteners to the correct torque For the specification refer to section 12 14 6 3 4 Install the cable gland plates Preliminary requirements 1 The door is open 2 The protection cover is removed Screwdriver cross Set of open spanners Procedure 1 Install the nuts ...

Page 44: ... Remove the AC covers Refer to section 10 4 b Connect the AC input cable Refer to section 7 3 c Install the AC covers 4 Connect the DC power cables a Remove the DC busbar cover Refer to section 10 3 b Connect the DC power cables Refer to section 7 4 c Install the DC busbar cover 5 Connect these cables a AC auxiliary power cable Refer to section 7 5 b Interlock and DC guard cables Refer to section ...

Page 45: ...hed washer D the cable lug B and the contact washer E 5 Connect these cables to the busbar 1 PE cable of the AC input cable 2 Cable from the charge post 3 If there is a secondary power cabinet PE cable from the secondary power cabinets 4 Lightning protection 6 Install a toothed washer D and a nut F on the bolt C from the bottom 7 Tighten the fasteners to the correct torque For the specification re...

Page 46: ...nuts to the correct torque For the specification refer to section 12 14 7 4 Connect the DC power cables Preliminary requirements Torque wrench Wire cutter Wire stripper pliers DC power cables two positive two negative Refer to section 12 4 Cable lugs Refer to section 12 4 Procedure 1 Cut the DC power cables to make sure that the length is sufficient for connection at the the DC busbars A and A 2 I...

Page 47: ... Strip the insulation from the ends of the wires A to D For the procedure refer to section 11 2 For the specification refer to section 12 19 4 2 Crimp ferrules onto the end of the wires Refer to section 11 2 Obey the ferrule manufacturer recommendations 3 Loosen the screws of the terminal block X 10 4 Connect these wires PE wire A green yellow to the terminal X10 1 E L1 wire B brown to the termina...

Page 48: ... Connect to terminal Terminal name A Ground wire or shield mesh Earthing terminal PE B Interlock IN X8 15 IL OUT 1 C Interlock OUT X8 14 IL IN 1 D DC guard GND X8 13 DC guard A1 GND E DC guard signal X8 12 DC guard A1 3 Connect wire loops F Between the terminals X8 10 and X8 11 G Between the terminals X8 6 and X8 7 18 17 16 19 21 22 20 24 23 15 14 13 12 11 10 9 8 7 6 5 4 X8 1 2 3 CanH_IN GND_CAN_I...

Page 49: ...rter B 2 Remove the protection covers from the optical connectors 3 Connect the CAN bus fiber cable Rx C from the charge post to connection Td E 4 Connect the CAN bus fiber cable Tx D from the charge post to connection Rd F 5 Do not connect the two remaining fiber cables These fiber cables are spares 6 Tie the CAN cables together a Tighten the loops of the cables with cable ties b Make sure that t...

Page 50: ...ect the cables to the charge post PE wires Refer to section 8 2 DC power cable Refer to section 8 3 AC auxiliary power cable Refer to section 8 4 Interlock and DC guard cable Refer to section 8 5 Optical CAN cable from the power cabinet Refer to section 8 6 Ethernet cable Refer to section 8 7 4 Install the protection plate 5 Close and lock the door of the charge post Refer to section 10 9 8 2 Conn...

Page 51: ... For the specification refer to section 12 14 8 3 Connect the DC power input cables Preliminary requirements Wire cutter Wire stripper pliers Spanner Torque wrench Torque screwdriver cross DC power cable Refer to section 12 19 2 Cable lugs Refer to section 12 4 Procedure 1 Cut the DC power cables A and B to make sure that the length is sufficient for connection at the DC busbars C and D 2 Strip th...

Page 52: ... AC auxiliary power cable Ferrules Note The AC auxiliary power cable provides the control power to the charge post Procedure 1 Strip the insulation from the ends of the wires A to D For the specification refer to section 12 19 4 2 Crimp ferrules onto the end of the wires 3 Loosen the screws of the terminals E to H of the terminal block X 10 4 Connect these wires PE wire A green yellow to the termi...

Page 53: ...on 12 21 Preliminary requirements Torque screwdriver cross Interlock and DC guard cable Refer to section 12 19 5 Ferrules Procedure X20 4 3 1 2 5 6 7 8 9 10 EXT_Interlock_In EXT_Interlock_Out PE DC guard GND DC guard signal GND V V Rout Rin E D C B A Electrical installation of the charge post 9AKK107992A3069 EN 004 53 ...

Page 54: ... D DC guard A1 X20 9 DC guard signal E DC guard A1 GND X20 10 DC guard GND Note The colors of the cables can be different in your equipment The colors in the illsutration are used to clarify the explanation and to distinguish the different cables 8 6 Connect the optical CAN cable Note The Rx and Tx lines must be swapped between the charge the post and the power cabinet Note For a detailed overview...

Page 55: ...Rx at A100 4 Do not connect the two remaining fiber cables These fiber cables are spares 5 Tie the CAN cables together a Tighten the loops of the cables with cable ties b Make sure that the loop bend radius is sufficient to prevent damage to the cable core For the specification refer to section 12 19 6 8 7 Connect the Ethernet cable Preliminary requirements Ethernet cable with an RJ45 plug Refer t...

Page 56: ...Procedure 1 Guide the cable A to the switch ethernet device B 2 Connect the RJ45 plug to the switch port X1 C A B C Electrical installation of the charge post 56 9AKK107992A3069 EN 004 ...

Page 57: ...atible connection If the EVSE has more than one connection type an EV of each type must be available The site operator or owner is available to receive instructions from the service engineer of the manufacturer 3 Make sure that this data is available Contact data of the contact person on site Address of the EVSE Site name Exact location of the EVSE longitude and latitude If there are more EVSEs on...

Page 58: ...r key Note There is one unique door key for each power cabinet Procedure 1 Turn the cover plate A 2 Insert the door key B 3 Turn the door key counterclockwise to unlock the door C 4 Pull the handle D 5 Turn the handle clockwise 6 Open the door 10 2 Remove the plinth covers of the power cabinet Preliminary requirements Set of open spanners D A B C 1 4 2 3 5 6 Access to parts 58 9AKK107992A3069 EN 0...

Page 59: ... B 10 3 Remove the DC busbar cover Preliminary requirements Screwdriver cross Procedure 1 Remove the fasteners A 2 Remove the cover B 10 4 Remove the AC covers Preliminary requirements Screwdriver cross B A B A A B A Access to parts 9AKK107992A3069 EN 004 59 ...

Page 60: ...e sure that only qualified personnel has access to the door key Note There is one unique door key for each cabinet Procedure 1 Close the door A 2 Turn the handle B counterclockwise 3 Push the handle 4 Turn the door key C clockwise to lock the door 5 Remove the door key C 6 Turn the cover plate D to cover the keyhole C B A A C B 6 3 5 4 2 1 D Access to parts 60 9AKK107992A3069 EN 004 ...

Page 61: ...y for each charge post The door of the charge post is under some pressure to make sure that it closes watertight Procedure 1 Insert the door key A 2 Turn the door key counterclockwise to unlock the door B 3 Pull the handle C 4 Turn the handle clockwise 5 Open the door 10 7 Remove the plinth covers of the charge post Preliminary requirements Set of hex keys A 1 2 3 4 5 C B Access to parts 9AKK10799...

Page 62: ...irements Screwdriver cross Procedure 1 Remove these parts Fasteners A Protection plate B 10 9 Close the door of the charge post Preliminary requirements Door key of the charge post Danger Hazardous voltage Make sure that only qualified personnel has access to the door key A A A B B B A Access to parts 62 9AKK107992A3069 EN 004 ...

Page 63: ... for each charge post Procedure 1 Close the door A 2 Turn the handle B counterclockwise 3 Push the handle 4 Turn the door key C clockwise to lock the door 5 Remove the door key C 5 4 3 2 1 A B Access to parts 9AKK107992A3069 EN 004 63 ...

Page 64: ...mpatible with the wire 2 Strip the insulation from the wire The stripped length must be the same as the length of the cavity of the cable lug 3 Insert the conductor of the wire into the cavity of the cable lug 4 Install the cable lug on the wire Use the crimp plier 11 2 Install a ferrule on a wire Preliminary requirements Wire cutter Wire stripper pliers Crimp plier Ferrule 1 2 2 B A Generic proce...

Page 65: ...e ferrule on the wire Use the crimp plier 11 3 Install insulating heatshrink tubing on a wire Preliminary requirements Heat gun Heatshrink tubing Procedure 1 Clean the part of the wire or the wire with the cable lug that you want to insulate 2 Cut a piece of heatshrink tubing Make sure that the length covers all electrical cables Use a diameter that is larger than the wire diameter 3 Install the p...

Page 66: ...pecification refer to section 12 14 4 Make sure that unused wires are protected and cannot touch metal parts 11 5 Connect a wire that has a ferrule Preliminary requirements Procedure 1 Loosen the screw of the connection on the terminal 2 Install the ferrule in the connection of the terminal 3 Tighten the screw to the correct torque For the specifications refer to section 12 14 4 Make sure that unu...

Page 67: ...k output power kW Examples HP CP500 C T HP Model Terra high power U CP500 Part charge post 500 A DC output V C EV charge cable connection one CCS connection HP 175 T HP Model Terra high power U Part power cabinet V 175 peak output power is 175 kW 12 2 Parts included in the delivery Parameter Specification Charge post Refer to the type plate Refer to section 3 2 Power cabinet Refer to the type plat...

Page 68: ... 12 2 Thread M10 for the charge post Thread M16 for the power cabinet Bolts Size M16 Hex keys Standard set of hex keys Open spanners Standard set of open spanners Torque socket wrench For the torque specifications refer to section 12 14 Screwdriver cross Size M5 8 mm 0 3 in Wire cutter Wire stripper pliers Crimp pliers 12 4 Required parts for installation Part Specification Fasteners and washers t...

Page 69: ...arge post FCC part 15 Class B residential EMC rating for the power cabinet The power cabinet complies with Class A industrial If the power cabinet must comply with Class B residential install an external Schaffner type FN 3359HV 400 99 EMC filter 12 6 Electrical installation specifications North America Parameter Specification Upstream overcurrent protection device Fuse gG type 300 A Surge protect...

Page 70: ...by status 70 W With the LEDs on 145 W Earthing rod initial Maximum 10 Ω Earthing rod additional 0 9 Ω Input AC power connection 600 347 3W PE Input grounding system wye Grounded system Input voltage range 600 VAC 10 50 Hz or 60 Hz Nominal input current 185 A at 600 VAC Power factor at full load 0 97 Efficiency 94 at 20 load 12 8 DC output specifications Parameter Specification Output voltage range...

Page 71: ...G or Sure Call device 1 Do not use a handheld mobile phone to measure the signal strength 2 Make sure that the cellular signal to the modem of the EVSE is of a serv iceable quality The Charger Connect service provides 4G connectivity via the Vodafone network As a result you must verify that one or more ap plicable bands at AT T or T Mobile falls or fall within an acceptable cate gory Examples 4G L...

Page 72: ...ification kg lbs Mass of the power cabinet 1400 3086 5 Mass of the charge post 250 551 2 12 11 2 Center of gravity power cabinet X Z Y A A Center of gravity Parameter Specification mm in X 587 23 1 Y 407 16 0 Z 1068 42 1 Technical data 72 9AKK107992A3069 EN 004 ...

Page 73: ... 9 6 Z 1096 43 2 12 12 Ambient conditions Parameter Specification Operation temperature 35 C to 55 C 31 F to 131 F Derating applies Storage 5 C to 40 C 41 F to 104 F RH 5 to 85 Environment IP54 rainproof IK10 screen IK08 Altitude Maximum 2000 m 6562 ft above the sea level Technical data 9AKK107992A3069 EN 004 73 ...

Page 74: ...er cabinet nuts on the DC power busbars 30 266 Charge post fasteners to the founda tion 80 708 Charge post fasteners on the PE busbar Between 33 and 44 Between 292 and 389 Charge post screws in the terminal blocks 1 3 11 5 DC input cable to the connector 30 265 5 M5 fasteners if not specified 3 5 31 0 M6 fasteners if not specified 9 79 7 M8 fasteners if not specified 20 177 M10 fasteners if not sp...

Page 75: ...ication mm in Width of the charge post X dimension 590 23 2 Depth of the charge post Y dimension 425 16 7 Height of the charge post Z dimension 2463 97 0 Required cable slack for the PE wire measured from the top of the founda tion 700 27 6 Required cable slack for the DC power cables measured from the top of the foundation 700 27 6 Required cable slack for the AC auxiliary power cable measured fr...

Page 76: ...or when holstered center of grip 775 30 5 Z4 CHAdeMO connector when hol stered center of grip 790 31 1 Z5 Top of the authentication clus ter 955 37 6 Z6 Bottom of the touch screen dis play 1026 40 Z7 Advised maximum height for user operable elements if the EVSE is placed on a curb This requires HMI customization 1118 44 Z8 Top of the touch screen display 1223 48 1 Technical data 76 9AKK107992A3069...

Page 77: ...2 Space for air inlet on the side X3 Space to open the power cabinet door Y1 Total depth required for the power cabinet Y2 Space to open the power cabinet door Y3 Space for air outlet Parameter Specification mm in X1 1170 47 2 X2 200 7 9 X3 650 25 6 Y1 770 30 3 Y2 1050 41 3 650 25 6 Y3 100 3 9 Technical data 9AKK107992A3069 EN 004 77 ...

Page 78: ... to open the door X5 Required width to open the side panel Y1 Space required for cable replacement Y2 Total required depth for the charge post Y3 Maximum sideway reach of the wheelchair user Y4 Space required to open the door Y5 Required depth to open the side panel Parameter Specification mm in X1 1490 58 7 X2 450 17 7 X3 105 4 1 X4 800 31 5 X5 345 13 6 Y1 400 15 7 Y2 775 30 6 Y3 254 10 Y4 490 19...

Page 79: ...open the side panels X2 Required width to open the side panel X3 Space required at the sides to open the door X4 Total required width to open the door Y1 Required depth to open the side panel Y2 Required depth to open the side panel Y3 Total required width to open side panels Y4 Space required to open the door Parameter Specification mm in X1 1190 46 8 X2 200 7 8 X3 105 4 1 X4 800 31 5 Y1 250 9 8 ...

Page 80: ...cabinet prefab concrete General specifications Parameter Specification Type Base monoblock of support for cabinet with plasticizer and waterproofing addi tive Concrete class C32 40 Exposure class CX4 and XD25 according to UNI 11104 2018 Dimensions side view Y5 a1 a1 Y4 Y1 Y2 Y3 Y8 Y7 Y9 Y10 Y11 Y12 Z2 Z1 Z3 a2 a2 D1 D2 Parameter Specification mm in Y1 120 4 72 Y2 930 36 6 Technical data 80 9AKK107...

Page 81: ...46 1 Y7 300 11 8 Y8 570 22 4 Y9 300 11 8 Y10 585 23 0 Y11 585 23 0 Y12 1170 46 1 Z1 200 7 87 Z2 185 7 28 Z3 720 28 3 D1 8x diameter 160 6 30 D1 4x diameter 90 3 54 Parameter Specification α1 93 α2 90 D1 hole 3 tapered D2 hole 3 tapered Technical data 9AKK107992A3069 EN 004 81 ...

Page 82: ...r Specification mm in X1 120 4 72 X2 120 4 72 X3 1000 39 4 X4 1300 51 2 X5 530 20 9 X6 770 30 3 X7 400 15 7 X8 625 24 6 X9 275 10 8 X10 775 30 5 X11 525 20 7 X12 1300 51 2 Z1 700 27 6 Z2 20 0 79 R all edges 3 0 1 Parameter Specification α1 93 α2 90 Technical data 82 9AKK107992A3069 EN 004 ...

Page 83: ...n mm in X1 250 9 84 X2 800 31 5 X3 250 9 84 X4 60 2 3 X5 680 1 26 8 0 1 X6 90 3 5 X7 410 1 16 1 0 1 X8 60 2 3 X9 100 3 94 X10 800 1 31 5 0 1 X11 100 3 94 X12 100 3 94 Y1 250 9 84 Y2 670 26 4 Y3 250 9 84 Y4 60 2 3 Y5 1050 1 41 3 0 1 Y6 60 2 3 Y7 100 3 94 Y8 670 1 26 4 0 1 Technical data 9AKK107992A3069 EN 004 83 ...

Page 84: ...n B Front cover C Rear gland plate D Left gland plate E Right gland plate F Cable trays G Tie plate X1 Width of the foundation Y1 Depth of the foundation Z1 Height of the foundation Parameter Specification X1 1170 mm 46 1 in Y1 770 mm 30 3 in Z1 203 1 mm 8 00 in Mass 63 7 kg 140 5 lb Fasteners to connect the power cabinet to the foundation included in the deliv ery 4 x M16 Class 10 9 length 30 mm ...

Page 85: ... Y1 Y1 Y2 Y1 X2 X3 X2 X1 X1 X4 X3 X4 X1 A B A Drilling area for the side gland plate B Drilling area for the rear gland plate Parameter Specification mm in X1 28 6 1 13 X2 269 9 10 63 X3 57 2 2 25 X4 409 6 16 13 Y1 28 6 1 13 Y2 127 5 00 Technical data 9AKK107992A3069 EN 004 85 ...

Page 86: ...shows the front side of the power cabinet Parameter Specification A 4x For M16 fasteners depth 60 2 4 Parameter Specification mm in X0 1170 46 1 X1 1050 41 3 X2 930 36 6 X3 60 2 4 X4 153 6 0 X5 409 16 1 X6 409 16 1 X7 108 4 3 Y0 770 30 3 Y1 680 26 8 Y2 748 29 4 Y3 49 1 9 Y4 133 5 2 Y5 63 2 5 Technical data 86 9AKK107992A3069 EN 004 ...

Page 87: ...onduit hole Cable conduit for these cables C1 AC power C2 None C3 CAN interlock and DC guard to the charge post C4 AC auxiliary and PE to the charge post C5 None C6 None C7 DC power to the charge post C8 DC power to the charge post 12 17 5 Charge post prefab concrete Foundation mass and loads Parameter Specification Mass 1030 kg 2271 lb Nd 15 06 kN 3386 klbf Vd 5 25 kN 1180 klbf Md 8 36 kNm 74 1 k...

Page 88: ...3 Z2 Z4 a1 Z5 Z6 Parameter Specification mm in X1 175 6 89 X2 640 25 2 Y1 220 8 66 Y2 157 5 6 20 Z1 30 1 2 Z2 500 19 7 Z3 200 7 87 Z4 162 5 6 40 Z5 282 5 11 1 Z6 428 16 9 Parameter Specification α1 3 Technical data 88 9AKK107992A3069 EN 004 ...

Page 89: ...00 39 4 Y1 125 4 92 Y2 150 5 91 Y3 150 5 91 Y4 1400 55 1 Y5 440 17 3 D1 diameter 125 4 92 D2 diameter 125 4 92 D3 diameter 60 2 36 Parameter Specification α1 3 Tube diameter for D1 125 119 mm 4 92 44 1 in Tube diameter for D2 125 119 mm 4 92 44 1 in Tube diameter for D3 60 56 mm 2 36 2 20 in Technical data 9AKK107992A3069 EN 004 89 ...

Page 90: ...late H Holes for the fasteners I Footprint of the foundation X1 Width of the foundation Y1 Depth of the foundation Z1 Height of the foundation X2 Distance between the holes X3 Distance between the hole and the edge of the footprint Y2 Distance between the holes Y3 Distance between the hole and the edge of the footprint Parameter Specification X1 620 mm 24 4 in Y1 440 mm 17 3 in Z1 152 mm 5 98 in X...

Page 91: ... in 12 17 7 Gland plates for the metal foundation of the charge post X1 Y1 Y2 Y1 Y1 Y2 Y1 X2 X1 X4 X5 X5 X4 B A A Drilling area for the side gland plate B Drilling area for the rear gland plate Parameter Specification mm in X1 15 9 0 63 X2 298 5 11 75 X3 19 1 0 75 X4 12 7 0 50 X5 177 8 7 00 Y1 19 1 0 75 Y2 89 9 3 50 Technical data 9AKK107992A3069 EN 004 91 ...

Page 92: ... front side of the charge post Parameter Specification A 6x For M12 fasteners diameter 14 0 6 Parameter Specification mm in X0 580 22 8 X1 526 20 7 X2 45 1 8 X3 436 17 X4 100 3 9 X5 110 4 3 X6 170 6 7 X7 85 3 3 Y0 371 14 6 Y1 150 5 9 Y2 26 1 0 Y3 248 9 8 Y4 70 2 8 Technical data 92 9AKK107992A3069 EN 004 ...

Page 93: ...0 C4 126 5 0 Function for cable conduit holes Cable conduit hole Cable conduit for these cables C1 AC auxiliary C2 CAN interlock and DC guard C3 DC power C4 DC power 12 18 Overview of the cable conduits Note For a detailed overview of the electrical connections refer to section 12 21 Technical data 9AKK107992A3069 EN 004 93 ...

Page 94: ... DC power D AC auxiliary power PE E CAN Interlock DC guard F AC power Cable conduit Maximum diameter mm in Small holes in the foundation of the power cabinet 90 3 54 Large holes in the foundation of the power cabinet 160 6 30 Small holes in the foundation of the charge post 60 2 36 Large holes in the foundation of the charge post 125 4 92 Technical data 94 9AKK107992A3069 EN 004 ...

Page 95: ...tion cables The below data are specific for the DC power cables between the power cabinet and the charge post Parameter Specification Type DLO Type W2 2 DC cables per DC and 2 DC cables per DC Flexible with voltage sensing lines Unshielded Number of cores 1 Cross section range minimum 125 mm 250 kcmil Cross section range maximum 300 mm 592 kcmil Diameter 27 to 35 mm 1 1 to 1 4 in Maximum length 60...

Page 96: ...trand copper wire according to VDE 0295 Cl 5 IEC 60228 Cl 5 Insulation Special PVC that is serviceable for out door use UV protected and oil resistant Minimum voltage rating Uo U 600 V Minimum test voltage 4 kV Ambient temperature range 40 C to 80 C 40 F to 176 F 12 19 4 AC auxiliary power cables Parameter Specification Number of cores 4 Cross section range 2 5 mm 14 AWG Shielding No Conductor Bar...

Page 97: ...he charge post Parameter Specification Number of cores 2 fibre cores for installation 2 fibre cores as spare parts Type OM3 multimode prefabricated Connector B FOC ST Diameter 13 to 21 mm 0 51 to 0 83 in Wave length 850 nm Material PCF or fiberglass Loop bend radius Minimum 64 mm 2 5 in Strip length 11 mm 0 43 in 12 19 7 Ethernet cable Parameter Specification Type Shielded tinned copper braid Numb...

Page 98: ...12 20 Expected wye input L1 L2 L3 PE N B A Canada USA A 600 V 480 V B 347 V 277 V Technical data 98 9AKK107992A3069 EN 004 ...

Page 99: ...above Signal connection Charge Cabinet Charge 3 phase Signal Connection Power Cabinet Charge Post Charge Post X20 4 3 1 TX RX X8 A100 D2 2 5 6 7 8 9 10 TX RX Power Cabinet Grounding electrode PE 2AWG if needed 1 2 3 12AWG BN 12AWG BK 12AWG GY DC X402 X400 DC PE 2AWG Grounding electrode if needed DC 1x250kcmil PE 2AWG Legend 480Y 277V From Utility DC 1x250kcmil A3 Size Sheet HLA Location Drawing No...

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