ABB Terra Mobile 44HV Operation And Installation Manual Download Page 21

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3.3.2

Working principle of the DC charging unit and the control unit

AC power input

Power module circuit breaker

Power module

Fan

Optional power module group

(Terra Mobile 54HV)

DC filter

DC switch matrix

DC fuse

CPI board

IMI board

DC charge cable

Auxiliary power supply

CCB board

Main control board

Touchscreen

RFID

RS485 source

Ethernet connection source

Emergency stop button

Auxiliary residual-current device

•

Red and bold lines: AC power connection

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Black and bold lines: DC power connection

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Black and thin lines: auxiliary power connection

•

Green lines: control signal or monitoring signal

•

Dashed lines: group of system components

Description

9AKK108467A6997-EN | 003

Summary of Contents for Terra Mobile 44HV

Page 3: ...eral safety instructions 13 2 3 Responsibilities for the owner 14 2 4 Required qualifications for the installation engineer 14 2 5 Personal protective equipment 14 2 6 Safety instructions during installation 15 2 7 Safety instructions during transport 15 2 8 Safety instructions for earthing 16 2 9 Safety instructions for use 16 2 10 Signs on the EVSE 16 2 11 Discard the EVSE or parts of the EVSE 1...

Page 4: ...Unpacking 31 4 2 1 Unpacking procedure 31 4 2 2 Unpack the EVSE 32 4 2 3 Do a check on the transport sensors 32 4 3 Packing 32 4 3 1 Pack the EVSE 32 4 4 Transport the EVSE on the site 33 4 4 1 Move the EVSE with a forklift truck 33 4 4 2 Hoist the EVSE 33 5 Installation 35 5 1 General installation procedure 35 5 2 Site preparation 35 5 2 1 Prepare the site 35 5 2 2 Control the space and airflow a...

Page 5: ...e 45 7 3 Clean the cabinet 45 7 4 Do a check for damage on the EVSE 46 7 5 Replace the air inlet filters 46 7 5 1 Replace the air inlet filter on the front 46 7 5 2 Replace the air inlet filter on the side 47 7 6 Replace the air outlet filter 48 8 Disconnect 49 8 1 Remove the AC input cable 49 9 Access to parts 50 9 1 Open the doors 50 9 2 Close the doors 50 10 Troubleshooting 52 10 1 Troubleshoot...

Page 6: ...t specifications Terra Mobile 44HV 59 11 15 3 AC input specifications Terra Mobile 54HV 59 11 15 4 General AC input cable specifications 59 11 15 5 AC input cable specifications Terra Mobile 44HV 59 11 15 6 AC input cable specifications Terra Mobile 54HV 60 11 15 7 Connector types for the AC input cable 60 11 16 DC output specifications 60 11 16 1 DC output specifications Terra Mobile 44HV 60 11 1...

Page 7: ...er refer to section 2 3 For the required qualifications for the installation engineer refer to section 2 4 1 3 Revision history Version Date Description 001 November 2021 Initial version 002 January 2023 Textual updates 1 4 Language The original instructions of this document are in English EN US All other language versions are translations of the original instructions 1 5 Illustrations It is not a...

Page 8: ...do not obey the instruction this can cause injury or death Refer to section 1 10 Warning If you do not obey the instruction this can cause injury Refer to section 1 10 Caution If you 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 p...

Page 9: ...s or signal words are present in this document 1 10 Special symbols for warnings and dangers Symbol Risk type 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 About this docume...

Page 10: ...abb com ev charging 1 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 proto...

Page 11: ...y 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 for communication with charge sta tions Owner Legal owner of the EVSE Protective devices Devices for the personal protection of individu...

Page 12: ... 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 12 9AKK108467A6997 EN 003 ...

Page 13: ...ation not complying to standards or installation not following the installation instructions contained in the product specific manual Improper operation in breach of the technical requirements or specifications or manuals of the product negligence or repairs carried out by the Owner or any third party not authorized by ABB Non compliance with the applicable safety regulations or other legal standa...

Page 14: ...according to the applicable local rules to do the work To make sure that there is sufficient space around the EVSE to safely do maintenance and installation work To identify a site operator who is responsible for the safe operation of the EVSE and for the coordination of all work if the owner does not do these tasks 2 4 Required qualifications for the installation engineer The qualified installati...

Page 15: ...ctly Refer to section 2 8 Make sure that the wiring inside the EVSE is protected from damage and cannot get trapped when you open or close the cabinet Make sure that water cannot enter the cabinet Protect the EVSE with safety devices and measures that the local rules specify If it is necessary to remove safety devices immediately install the safety devices after the work Put on the correct persona...

Page 16: ...d to the equipment grounding terminal or lead on the product Make sure that the connections to the EVSE comply with all applicable local rules 2 9 Safety instructions for use Do not use the EVSE and immediately get in contact with the manufacturer if the safety or the safe use of the EVSE is at risk This includes but is not limited to these conditions An enclosure has damage An EV charge cable or ...

Page 17: ...aterial or the EVSE Discard electrical and electronic equipment separately in compliance with the WEEE 2012 19 EU Directive on waste of electrical and electronic equipment As the symbol of the crossed out wheeled bin on your EVSE indicates do not mix or dispose the EVSE with your household waste at the end of use Instead hand the EVSE over to your local community waste collection point for recycli...

Page 18: ...the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information The manufacturer ABB E mobility B V and 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 S...

Page 19: ...Internal product code for the manufacturer F Full EVSE type G EVSE mass H EVSE rating I Address of the manufacturer J CE mark K Barcode with the serial number of the EVSE L Barcode with the part number of the EVSE M Additional EVSE rating data Note Find the type plate on your EVSE to see the applicable data Refer to section 3 4 2 3 2 Intended use The EVSE is intended for the DC charging of EVs The...

Page 20: ...aker E Miniature circuit breaker F AC 22 kW socket G AC charge cable H EV I AC filter J Residual current device K DC charging module L DC charge cable M Residual current circuit breaker for the auxiliary AC circuit N Auxiliary surge protection device O Auxiliary AC residual current device P Auxiliary power supply Q Control unit R Heater Red and bold lines AC power connection Black and bold lines D...

Page 21: ... H DC fuse I CPI board J IMI board K DC charge cable L EV M Auxiliary power supply N CCB board O Main control board P Touchscreen Q RFID R RS485 source S Ethernet connection source T Emergency stop button U Auxiliary residual current device Red and bold lines AC power connection Black and bold lines DC power connection Black and thin lines auxiliary power connection Green lines control signal or m...

Page 22: ... The EV of which the batteries need to be charged EVSE Refer to section 11 1 Charging area Location for the EV during the charge session AC input cable To supply the electrical energy to the EVSE Power distribution board To connect the EVSE to the AC grid input AC or DC charge cable To conduct the charge from the EVSE to the EV Description 22 9AKK108467A6997 EN 003 ...

Page 23: ...nside of the EVSE Wheels with brakes or floor locks To move the EVSE to the site and secure the EVSE on the site Emergency stop button To stop the EVSE when there is an emergency RFID reader To read the information from an RFID card Payment terminal To pay for the charge session Touchscreen To control and monitor the charge session Air inlet and outlet To let cooling air in and out The airflow mak...

Page 24: ...J Auxiliary power supply K AC output contactor L DC residual current circuit braker M DC surge protection device N Miniature circuit breaker of the AC output O Residual current device Part Function Fans To circulate air in the enclosure Power modules To convert the AC input power to the DC output power Main power module break ers To connect or disconnect the AC power input to the power modules AC ...

Page 25: ... without authorization An authorization can be based on RFID a personal identification number or a mobile authentication method Authorization requires a subscription to a back office Authorization can be a standard solution from the manufacturer or from an external company that offers authorization solutions via OCPP 3 6 Options 3 6 1 EV charge cable CCS 2 The manufacturer delivers the EVSE with C...

Page 26: ...than 50 of the maximum output of the AC socket for the 22kW outlet the remaining power must be more than 11 kW 30 A 400 V If the input current can not be more than 3x 100A the charge session on the 22kW outlet can start the charge session when the remaining power is more than 16 5 kW 43 A 400 V The message Waiting for power to be available is shown on the screen when the remaining power is less th...

Page 27: ...rrent device and the incidental current peaks refer to sections 11 15 and 11 19 3 9 Description of the touchscreen 3 9 1 General description of the layout A B C D A Company logo B Main display area C Touchscreen control bar D Available connectors on the EVSE 3 9 2 General description of the buttons Button Name Description XX kW YZ Connector To select the connector X Charge power Y Connector locati...

Page 28: ... stop the charge session 3 10 Local service portal 3 10 1 Local Service Portal The Local Service Portal is a service tool available on the EVSE for these purposes provide information about the EVSE allow for the configuration of the key parameters during commissioning enable diagnostic on site For the operation procedures refer to section 6 7 Description 28 9AKK108467A6997 EN 003 ...

Page 29: ... to go to the Hardware test screen Action button Trigger discovery to install new software Hardware test screen To navigate to various hardware tests Configuration main screen To set the following data Authorization on or off Maximum AC input current To set the configuration parameters refer to section 6 7 2 OCPP settings screen To set the following data OCPPJURL OCPPJID OCPPJPassword Confirm pass...

Page 30: ...s Out of order When the search is finished the local service portal starts The user interface is in idle mode Hardware To see details about the different boards Configuration To set parameters for the configure settings on the EVSE Toggle To select an option Set OCPP parameters To confirm the parameters for the configuration set tings that you entered Description 30 9AKK108467A6997 EN 003 ...

Page 31: ...l protective equipment PPE and follow all the applicable Health and Safety measures applicable to the working area Check the position of the center of gravity before lifting the EV Charger the higher the position of center of gravity the more care is required to handle the EV Charger to avoid overturning Check that the pallet is not damaged Otherwise please contact the responsible Health and Safet...

Page 32: ... 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 For the transport specifications refer to section 11 12 a Refuse the delivery of the EVSE b Make a note on the delivery receipt c Within three days of the delivery ask the transpo...

Page 33: ...ift the EVSE safely Obey the safety instructions that apply to the forklift truck Take into account the mass the dimensions and the center of gravity of the EVSE Refer to chapter 11 Caution Do not drop the EVSE Do not tilt the EVSE more than allowed Refer to section 11 12 Procedure 1 Move the forks A of the forklift truck in the gaps of the pallet 2 Move the EVSE to the correct location 4 4 2 Hois...

Page 34: ... Make sure that there are no dynamic forces on the hoisting points Make sure that the weight is equally distributed between the hoisting points Procedure 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 wi...

Page 35: ...or commissioning Refer to section 5 4 5 2 Site preparation 5 2 1 Prepare the site Preliminary requirements Installation engineer Procedure 1 Make sure that the space and the airflow around the EVSE is sufficient Refer to section 11 13 2 2 If the local rules require the installation of an external residual current device install an external residual current device Refer to section 3 8 3 Design the ...

Page 36: ...rical installation 5 3 1 Connect the AC input cable Preliminary requirements Installation engineer Preliminary requirements The AC cable has the required connector installed For the specification refer to section 11 15 4 Procedure 1 Connect the AC input cable A to the AC input terminal B 5 4 Prepare for commissioning Preliminary requirements Installation engineer A B Installation 36 9AKK108467A699...

Page 37: ...acturer 3 Make sure that these requirements are met You are present during the commissioning for assistance and to energize the power to the EVSE on the power distribution board An EV is available with a compatible connection The site operator or owner is available to receive instructions from the service engineer of the manufacturer 4 Make sure that this data is available Contact data of the cont...

Page 38: ...Make sure that you have approval of the manufacturer to use the EVSE after commissioning After approval do not move the EVSE 5 Make sure that the space around the EVSE cannot get blocked Think of snow or other objects Refer to the floor space requirements Refer to section 11 13 2 6 Make sure that maintenance is done on the EVSE Refer to section 7 1 7 If the EVSE is de energized for more than two h...

Page 39: ...iminary requirements Owner Installation engineer Procedure 1 Open the front door Refer to section 9 1 2 Set the main switch to the 1 position vertical Warning General hazard Be careful and use both your hands to turn the main switch You need some force to turn the switch 3 Close the front door Refer to section 9 2 The EVSE starts The display shows a message when the EVSE is ready for operation 6 5...

Page 40: ...hat the touchscreen shows The EVSE charges the EV and shows the progress on the touchscreen The status panel shows the status of the EVSE 6 5 3 Stop a charge session 1 On the touchscreen press the stop button Note When the battery is full the charge session stops automatically 2 Disconnect the EV charge cable from the EV Note In some cases the EV locks the connector to the EV To unlock the connect...

Page 41: ... 1 The HMI starts the local service portal application The outside HMI goes into idle mode On the inside HMI the authorization screen shows 2 Enter the pin code The PIN code is an alphanumeric code 1234WWYYSSS The meaning of the letters and numbers is 1234 fixed code WW production week YY production year SSS serial number 3 Select Continue 6 7 2 Set the configuration parameters 1 Go to the configu...

Page 42: ...this discovery the local service portal is closed The screen shows the message Out of order 2 Do not turn off the EVSE during the discovery process 3 Wait until the discovery process is finalized The discovery of new hardware can take up to 15 minutes At the end of the discovery process the new software is installed The system starts the processes again in the background and the screen goes into i...

Page 43: ...or the air inlets 1 year or if needed due to harsh ambient conditions Refer to section 7 5 Make sure that the manu facturer does maintenance on the EVSE 1 year Ask the manufacturer to do the task Refer to sec tion 1 12 For the complete mainte nance schedule refer to section 11 5 For the required spare parts refer to section 11 10 Replace the filters for the air outlets After the first year then 2 ...

Page 44: ...tages are 0 V 6 Measure the DC voltage Refer to section 7 2 3 7 Make sure that all the measured voltages are 0 V 8 Close the front and the right door Refer to section 9 2 7 2 2 Measure the AC voltage Preliminary requirements Installation engineer Owner Only do this procedure if a different procedure refers to this procedure AC and DC tester Procedure 1 Measure the AC voltage between the terminals ...

Page 45: ...sive tool Refer to section 11 11 Danger Hazardous voltage Do not apply high pressure water jets Water can leak into the cabinet Note When the EVSE is put in a corrosion sensitive environment superficial rust is possible on welding points This rust is only visual There is no risk for the integrity of the cabinet The procedure below removes the rust Procedure 1 Rinse with low pressure tap water to r...

Page 46: ...racks or ruptures Internal wires of the cable are visible AC input terminals Cracks or ruptures Touchscreen Cracks Touchscreen does not work Coating of the cabinet Cracks or ruptures Cabinet Signs of rust that are caused by water that went into the cabinet Loose fasteners at the bottom of the EVSE 2 If you see damage contact the manufacturer Refer to section 1 12 7 5 Replace the air inlet filters ...

Page 47: ... inlet filter on the side Preliminary requirements The EVSE is de energized Refer to section 7 2 Spanner Owner Air inlet filters Refer to section 11 10 Procedure 1 Open the the right door Refer to section 9 1 2 Remove the nuts A Use the spanner 3 Carefully remove theses parts 1 Cover B 2 Air inlet filter C Caution Prevent contamination of other parts of the EVSE Make sure that contamination on the...

Page 48: ...tion 9 1 2 Remove the nuts A Use the spanner 3 Carefully remove theses parts 1 Cover B 2 Air outlet filter C Caution Prevent contamination of other parts of the EVSE Make sure that contamination on the filter does not come off 4 Install these parts 1 Clean air outlet filters 2 Cover B 5 Install the nuts 6 Close the rear door Refer to section 9 2 A B C A A A Maintenance and cleaning 48 9AKK108467A6...

Page 49: ...8 Disconnect 8 1 Remove the AC input cable Preliminary requirements Installation engineer Procedure 1 Remove the cable A from the AC input terminal B A B Disconnect 9AKK108467A6997 EN 003 49 ...

Page 50: ... front door A unlock the lock B Use the door key 2 To open the right door C unlock the lock D Use the door key 3 To open the rear door E unlock the lock F Use the door key 9 2 Close the doors Preliminary requirements Installation engineer Service engineer Owner Door key Danger Hazardous voltage Make sure that only qualified persons have access to the door key A B C F D E Access to parts 50 9AKK108...

Page 51: ...se the lock B and the door key 2 For the right door a Close the right door C b Lock the right door Use the lock D and the door key 3 For the rear door a Close the rear door E b Lock the rear door Use the lock F and the door key A B C F D E Access to parts 9AKK108467A6997 EN 003 51 ...

Page 52: ... The EV charge cable is not connected correctly to the EV Connect the DC charge ca ble to the EV correctly The touchscreen shows this message Unable to unlock the connector from car A dangerous voltage is present on the DC charge cable 1 Wait 5 minutes 2 Start the charge ses sion again Refer to section 6 5 2 The touchscreen shows this message Insulation detection error There is an insulation probl...

Page 53: ...the AC input cables is installed cor rectly Refer to section 5 3 1 2 Contact your on site representative of the manufacturer One of the doors is open 1 Make sure the doors are closed Refer to section 9 2 2 Contact your local rep resentative of the man ufacturer Troubleshooting 9AKK108467A6997 EN 003 53 ...

Page 54: ...C CCS 1 and CCS 2 connection G Type 2 AC power over a connected cable up to 43 kW and 3 phases T Type 2 AC power over a socket up to 22 kW and 3 phases S EV charge cable length 3 3 m T A Air cooled EV charge cable s U Power rating 2 Max 200 A current V Product line Cube W Certification CE IEC compliant 11 2 Parts included in the delivery Parameter Specification EVSE Refer to the type plate Refer t...

Page 55: ...y and the maximum tilt angle Refer to sections 11 13 11 7 11 8 and 11 12 11 5 Maintenance schedule for the service engineer Part name Years after startup 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Filter inlet kit R R R R R R R R R R R R R R R Filter outlet kit R I R I R I R I R I R I R I R Fan cabinet I I I I R I I I I R I I I I R Power module I I I I I I I I I R I I I I I DC fuse I I I I R I I I I R ...

Page 56: ...esponsible to ensure that the unit is used within its operation range 11 7 Mass Parameter Specification kg Mass with packaging and DC cables 360 kg 11 8 Center of gravity location Parameter Specification mm Specification in X Y Z X Y Z Unpacked EVSE 450 900 380 17 7 35 4 15 Note The coordinates correspond with the agreements in section 1 15 0 0 0 is the left bottom front side of the EVSE 11 9 Nois...

Page 57: ...ive tool Non woven nylon hand pad 11 12 Transport specifications Parameter Specification Maximum tilt angle during transport 30 11 13 Dimensions 11 13 1 General dimensions Parameter Specification mm in Width of the cabinet X dimension 925 36 4 Depth of the cabinet Y dimension 1250 49 2 Height of the cabinet Z dimension 1290 50 8 Parameter Specification m ft Length of the charge cable air cooled 3 ...

Page 58: ...Parameter Specification mm in X1 2600 102 4 X2 900 35 4 Y1 1550 61 Y2 600 21 7 Y3 0 0 11 14 Communication interface specifications Parameter Specification RFID standard ISO 14443 A B to part 4 and ISO IEC 15693 RFID supported applications Mifare NFC Calypso Ultralight Pay Pass HID For information about the op tions contact the manufacturer Network connection 3G 4G modem Technical data 58 9AKK10846...

Page 59: ...bile 54HV Parameter Specification Maximum rated input current 78 A Recommended input circuit breaker 80 A Maximum power dissipation 54 kVA 11 15 4 General AC input cable specifications Parameter Specification Surface and diameter Based on current rating of the EVSE and local regulations Material Copper Maximum temperature of the input ca bles 75 C 167 F Minium length n 1 m where n is the distance ...

Page 60: ...arameter Specification Connector type on the cable IEC 60309 3P N PE 125 A female plug 11 16 DC output specifications 11 16 1 DC output specifications Terra Mobile 44HV Parameter Specification DC output voltage range 200 920 V Minimum DC output current 43 A Connection standard CCS IEC 61851 23 2014 IEC62196 1 2014 IEC 62196 3 2014 DC output power on one EV charge cable Maximum 40 kW DC output powe...

Page 61: ...ty Voltage V Current A Power kW 800 50 40 900 44 40 920 43 40 Output current in function of output voltage 0 20 40 60 80 100 120 140 0 200 400 600 800 1000 I A V V CCS 2 200A Technical data 9AKK108467A6997 EN 003 61 ...

Page 62: ...ion standard CCS IEC 61851 23 2014 IEC62196 1 2014 IEC 62196 3 2014 DC output power on one EV charge cable Maximum 50 kW DC output power on two EV charge ca bles Maximum 50 kW Simultaneous DC on 2 outlets No Only subsequent operation of the outputs available Maximum DC output current 125 A Charger Capacity Voltage V Current A Power kW 150 125 19 200 125 25 300 125 38 400 125 50 500 100 50 600 83 5...

Page 63: ...apacity Voltage V Current A Power kW 900 56 50 920 54 50 Output current in function of output voltage 0 20 40 60 80 100 120 140 0 200 400 600 800 1000 I A V V CCS 2 200A Technical data 9AKK108467A6997 EN 003 63 ...

Page 64: ...umption during stand by Parameter Specification kVA Stand by power heater off 0 08 Stand by power heater on 0 98 Note The heater will operate daily when the outside air reaches the dew point to avoid condensation inside the cabinet When the heater operates the heater will use most of the required standby power Power consumption during operation Parameter Specification kVA Power consumption 43 Terr...

Page 65: ...nt peaks during the start of a charge session Parameter Specification µs Duration of the current peaks 25 Maximum current peak 400V 50 Hz Parameter Specification A Maximum current peak 440 Technical data 9AKK108467A6997 EN 003 65 ...

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ABB Terra Mobile 44HV, Operation And Installation Manual, Page: 21 / 66

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