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Installation manual

Terra HP Generation 3 CE 175 kW Static

DC system

Содержание Terra HP Generation 3 CE

Страница 2: ...Copyright All rights to copyrights registered trademarks and trademarks reside with their respective owners Copyright ABB E Mobility B V All rights reserved 2 9AKK107992A2254 EN 005...

Страница 3: ...reements 13 2 Safety 14 2 1 Liability 14 2 2 General safety instructions 14 2 3 Required qualifications for the installation person 14 2 4 Personal protective equipment 15 2 5 Safety instructions duri...

Страница 4: ...m foundation for the charge post 30 5 Inspection and transport 32 5 1 Transport the EVSE to the site 32 5 2 Inspect the EVSE on delivery 32 5 3 Do a check on the transport sensors 32 5 4 Unpack the EV...

Страница 5: ...nect 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 8 8...

Страница 6: ...12 15 Dimensions 75 12 15 1 Power cabinet 75 12 15 2 Charge post 75 12 15 3 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 Cha...

Страница 7: ...12 19 8 Ethernet cable 93 12 20 Electrical connection diagram 95 Contents 9AKK107992A2254 EN 005 7...

Страница 8: ...nstructions of this document 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 you...

Страница 9: ...u 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 bef...

Страница 10: ...ol 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 o...

Страница 11: ...the contact data here https new abb com ev charging 1 14 Abbreviations Abbreviation Definition AC Alternating current BESS Battery energy storage system CAN Controller area network CPU Central proces...

Страница 12: ...actor 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 electr...

Страница 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 upwar...

Страница 14: ...d 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 contradicti...

Страница 15: ...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 Pr...

Страница 16: ...al 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 equipm...

Страница 17: ...s The identifier labels help EV owners to select the correct EV charge connector for their EV or the correct charger socket for the EV charge cable of the EV These labels for Identification of vehicle...

Страница 18: ...aste collection point for recycling For more information contact the Government Waste Disposal department in your country 2 11 Cyber security Note This topic is valid for a wired Ethernet connection T...

Страница 19: ...te 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...

Страница 20: ...Substation Power cabinet Charge 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...

Страница 21: ...onnections 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 Desc...

Страница 22: ...r cables Cable inlet A plate with openings for cables PE busbar To connect PE cables AC power connector To connect to the AC input power cable Main switch To connect or disconnect the AC power X 10 te...

Страница 23: ...ation 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 s...

Страница 24: ...e 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...

Страница 25: ...rules require an immunity for short current peaks over PE during the EV charging process At the start of the EV charge cycle a relay switches and engages the AC input power to the power modules Incid...

Страница 26: ...d from the power cabinets to the charge post This power supply is not included in the scope of ABB E Mobility B V ABB E Mobility B V recommends to use an uninterruptible power supply It is possible to...

Страница 27: ...al rules require the installation of extra items plan the installation of these items Examples External residual current device Refer to section 3 6 Options Refer to section 3 7 4 2 Prepare the site 1...

Страница 28: ...ts Refer to section 12 16 2 Make sure that the air flow inlet and outlet cannot get blocked Think of snow or objects 4 4 Prepare the foundation 4 4 1 Prepare the foundation general procedure 1 Select...

Страница 29: ...ion with gravel or another substance to prevent rodents to enter the cabinet 4 4 3 Prepare a custom foundation for the power cabinet Preliminary requirements Custom foundation Refer to section 12 17 2...

Страница 30: ...or 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...

Страница 31: ...foundations For the relation between the cables and the holes refer to section 12 17 4 3 Install the foundation in the hole 4 Put the cables through the openings in the foundation Apply the full cabl...

Страница 32: ...ensors 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...

Страница 33: ...e vertical position Refer to section 5 5 2 Move the charge post with a forklift truck Refer to section 5 5 3 Hoist the charge post Refer to section 5 5 4 5 5 2 Tilt the charge post to the vertical pos...

Страница 34: ...d Refer to section 5 4 Forklift truck Refer to section 12 3 Warning Risk of pinching or crushing the cabinet is heavy Make sure that the forklift truck can lift the cabinet safely Obey the safety inst...

Страница 35: ...EVSE Refer to sections 12 10 and 12 15 Caution Do not drop the cabinet Make sure that there are no dynamic forces on the hoisting points Make sure that the weight is equally distributed between the ho...

Страница 36: ...Procedure 1 Remove the fasteners A 2 Discard the fasteners and the pallet Refer to section 2 10 A Inspection and transport 36 9AKK107992A2254 EN 005...

Страница 37: ...section 7 4 Do the electrical installation of the charge post Refer to section 5 Prepare for commissioning Refer to section 9 6 2 Mechanical installation of the power cabinet 6 2 1 Install the power...

Страница 38: ...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 t...

Страница 39: ...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 t...

Страница 40: ...he charge post a Remove the plinth covers of the charge post Refer to section 10 7 b Open the door of the charge post Refer to section 10 6 c Remove the protection plate of the charge post Refer to se...

Страница 41: ...truck Torque wrench Six fasteners M12 and washers Drop in anchors for easy installation and quality Procedure 1 Carefully lower the charge post on the foundation with a hoisting equipment or a forkli...

Страница 42: ...he protection cover is removed Screwdriver cross Set of open spanners Procedure 1 Install the nuts A of the cable glands over the cables 2 Install these parts a Cable gland plates B b Fasteners C 3 Ti...

Страница 43: ...efer 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 c...

Страница 44: ...s 4 On the bolt C install the toothed 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...

Страница 45: ...orrect torque For the specification refer to section 12 14 7 4 Connect the DC power cables static 175 kW system Preliminary requirements Torque wrench Wire cutter Wire stripper pliers DC power cables...

Страница 46: ...e post Procedure 1 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 6 2 Crimp ferrules onto the end of the wi...

Страница 47: ...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 X...

Страница 48: ...ioned in the below table Use the illustration as a reference For the optical CAN cable specifications refer to section 12 19 6 Wire from charge post Connect to power cabinet A CAN bus fiber cable Rx C...

Страница 49: ...es 3 Loosen the screws of the terminal block X 1 4 Connect these wires V wire A from the external customer interface wire number 1 to the terminal X1 1 I V wire C from the external customer interface...

Страница 50: ...the charge post PE wire 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...

Страница 51: ...torque 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 p...

Страница 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 specificati...

Страница 53: ...n 12 20 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 gua...

Страница 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 explan...

Страница 55: ...x 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 r...

Страница 56: ...7 Ferrules Procedure 1 Strip the insulation from the ends of the wires A to D For the specification refer to section 12 19 7 2 Crimp ferrules onto the end of the wires 3 Loosen the screws of the termi...

Страница 57: ...ible 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 manu...

Страница 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...

Страница 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 cros...

Страница 60: ...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...

Страница 61: ...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 doo...

Страница 62: ...rements 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 vol...

Страница 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 t...

Страница 64: ...patible 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 c...

Страница 65: ...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...

Страница 66: ...ecification 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...

Страница 67: ...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 po...

Страница 68: ...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...

Страница 69: ...nput power M12 39 1 5 70 2 7 DC power M12 39 1 5 70 2 7 Charge post PE M8 22 0 9 40 1 6 M6 12 0 5 40 1 6 DC power M12 39 1 5 40 1 6 12 5 General specifications Parameter Specification Compliance and s...

Страница 70: ...tandards EN 61000 6 4 2007 A1 Emission standard for industrial environments Class A EN 61000 6 2 2005 Immunity for in dustrial environments If the power cabinet must comply with Class B residential in...

Страница 71: ...ut current 308 A at 360 V AC Power factor at full load 0 97 Efficiency 94 at 20 load 94 at 20 load 8 for 90 kW output power 12 7 DC output specifications Parameter Specification Output voltage range 1...

Страница 72: ...rent peak 60 A 12 10 Mass and center of gravity 12 10 1 Mass Parameter Specification kg lbs Mass of the power cabinet 1400 3086 5 Mass of the charge post 250 551 2 12 10 2 Center of gravity power cabi...

Страница 73: ...sensor specifications option Parameter Specification Tilt to disable the power from the low voltage source 10 12 12 Ambient conditions Parameter Specification Operation temperature 35 C to 55 C 31 F...

Страница 74: ...Power cabinet nuts on the AC power busbars 30 266 Power cabinet screws in the terminal blocks 1 3 11 5 Power cabinet nuts on the DC power busbars 30 266 Charge post fasteners to the founda tion 80 70...

Страница 75: ...quired cable slack for the interlock and DC guard and CAN cables meas ured from the top of the foundation 2000 78 7 12 15 2 Charge post Parameter Specification mm in Width of the charge post X dimensi...

Страница 76: ...fication m ft Length of the charge cable with retrac tion system 5 3 9 8 Cable reach approximately 3 118 12 15 3 Height of user operable elements Z1 Z4 Z6 Z5 Z8 Z7 Z3 Z2 Parameter Specification mm in...

Страница 77: ...op of the touch screen display 1223 48 1 12 16 Space requirements 12 16 1 Power cabinet Y2 Y1 X3 Y3 X2 X2 X1 A A Power cabinet X1 Total width required for the power cabinet X2 Space for air inlet on t...

Страница 78: ...panel X3 Space required at the sides to open the door X4 Total required width to open the door X5 Required width to open the side panel Y1 Space required for cable replacement Y2 Total required depth...

Страница 79: ...to permit service or maintenance operations Y4 Y3 X1 X3 X2 X2 A X3 Y1 Y2 X4 Y2 A Charge post X1 Total width to open the side panels X2 Required width to open the side panel X3 Space required at the si...

Страница 80: ...ication m ft Maximum distance between the power cabinet and the charge post 60 197 12 17 Foundation specifications 12 17 1 Power cabinet prefab concrete General specifications Parameter Specification...

Страница 81: ...Specification mm in Y1 120 4 72 Y2 930 36 6 Y3 120 4 72 Y4 928 36 5 Y5 870 34 3 Y6 1170 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...

Страница 82: ...X3 a1 a1 X1 X2 Y8 Y7 Y9 Y10 Y11 Y4 Z1 Z2 a2 a2 R X5 X6 X4 Parameter 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 X...

Страница 83: ...ions top view Y4 Y9 Y7 Y2 Y1 Y3 X2 X1 X3 X10 X9 X11 X5 X6 X4 X7 X8 Y5 Y6 Y8 C A B Parameter Specification 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...

Страница 84: ...3 94 Y10 100 3 94 Parameter Specification A 4x T Fixx M16 depth 80 3 1 RVS B 4x T Fixx M10 depth 65 2 6 RVS C 4x T Fixx M10 depth 65 2 6 RVS 12 17 2 Power cabinet custom Y5 Y6 Y6 Y1 X1 X3 X2 Y3 Y2 Y4...

Страница 85: ...748 29 4 Y3 49 1 9 Y4 133 5 2 Y5 63 2 5 Y6 70 2 8 Y7 63 2 5 Y8 70 2 8 Cable conduit hole Maximum diameter mm in C1 160 6 3 C2 60 2 4 C3 60 2 4 C4 60 2 4 C5 125 4 9 C6 125 4 9 C7 125 4 9 Function for c...

Страница 86: ...oundation 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 klb in Dimensions side views Z1 X1 X2 Y2 Y1 Z3 Z2 Z4 a1 Z5 Z6 Paramete...

Страница 87: ...meter Specification 1 3 Dimensions top view X5 X2 X4 X1 X3 Y3 Y2 Y1 Y4 Y5 B D1 D2 A Parameter Specification mm in X1 145 5 71 X2 120 4 72 X3 263 10 4 X4 1000 39 4 Y1 125 4 92 Y2 150 5 91 Y3 150 5 91 Y...

Страница 88: ...in Tube diameter for D3 60 56 mm 2 36 2 20 in A 2x DEMU anchor type 1988 type M16 depth 20 8 66 B 6x DEMU T FIXX A4 anchor type M12 depth 115 4 53 12 17 4 Charge post custom Y X6 X5 X4 X7 X3 X2 X1 Y2...

Страница 89: ...conduit hole Maximum diameter mm in C1 60 2 4 C2 60 2 4 C3 126 5 0 C4 126 5 0 Function for cable conduit holes Cable conduit hole Cable conduit for these cables C1 AC auxiliary and PE C2 CAN interloc...

Страница 90: ...C 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...

Страница 91: ...ta are specific for the DC power cables between the power cabinet and the charge post Parameter Specification Type 1x Positive 1x negative cable Flexible Unshielded Number of cores 1 Cross section ran...

Страница 92: ...ross section range 2 5 mm 14 AWG Shielding No Conductor Bare copper fine wired brunch stranded according to VDE 0295 CI 5 IEC CI 5 Insulation Special PVC that is serviceable for out door use UV protec...

Страница 93: ...mm 0 43 in 12 19 7 Cable for the tilt sensor control Note The tilt sensor control cables must be suitable for a 600 V environment Parameter Specification Number of cores 2 x 2 twisted pair 4 core Diam...

Страница 94: ...tion PVC that is serviceable for outdoor use UV protected and oil resistant Characteristic impedance 120 10 Voltage rating 600 VAC Test voltage 1 5 kV Ambient temperature range 40 C to 80 C Technical...

Страница 95: ...K 2 5mm GY DC X402 X400 DC Signal Connection Power Cabinet Charge Post Charge Post EXT_Interlock_In EXT_Interlock_Out PE X20 4 3 PE CanH_IN GND_CAN_IN CanL_IN DC Guard B 1 TX RX X8 A100 D2 2 5 6 7 8 9...

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