ABB Terra 54 Series User manual

—
MANUAL
Terra 54 / 54HV charger
Installation Manual

Notice
This document contains information about one or more ABB products and may include a descrip-
tion of or a reference to one or more standards that may be generally relevant to the ABB products.
The presence of any such description of a standard or reference to a standard is not a representa-
tion that all of the ABB products referenced in this document support all of the features of the de-
scribed or referenced standard. In order to determine the specific features supported by a particu-
lar ABB product, the reader should consult the product specifications for the particular ABB
product.
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erty in the ABB products described in this document.
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All rights to copyrights, registered trademarks, and trademarks reside with their respective
owners.
Copyright © 2018 ABB.
All rights reserved.

Contents
Glossary...............................................................................................................................................................5
1Introduction ...................................................................................................................................................6
1.1 Preface................................................................................................................................................................6
1.2 Intended document users ..............................................................................................................................6
1.3 Similarities and differences between Terra 24 and Terra 54..................................................................6
1.4 Terra version description ............................................................................................................................... 7
1.5 Signs.................................................................................................................................................................... 7
1.5.1 Owner responsibilities ..................................................................................................................8
1.5.2 Tilting and handling.......................................................................................................................8
1.5.3 Sharp edges.....................................................................................................................................8
1.5.4 Electric hazards .............................................................................................................................. 9
1.5.5 Installation safety........................................................................................................................... 9
1.6 1.6 Environment and disposal of waste ......................................................................................................9
2Description of the product.........................................................................................................................10
2.1 Overview of the system................................................................................................................................ 10
2.1.1 Complete overview ...................................................................................................................... 10
2.1.2 Outside view...................................................................................................................................11
2.1.3 Inside view ......................................................................................................................................11
2.2 Geometry of infrastructure ......................................................................................................................... 12
2.2.1 Required space for placing and maintaining the Terra 54 .................................................. 12
2.2.2 Ventilation and airflow of the Terra 54.................................................................................... 12
2.2.3 Bollards........................................................................................................................................... 13
2.3 Electrical engineering ................................................................................................................................... 14
2.3.1 Requirements External RCD....................................................................................................... 14
2.3.2 Conductor and cable diameter ................................................................................................. 15
3Site design.................................................................................................................................................... 17
3.1 Cable reach.......................................................................................................................................................17
3.2 Different alignment possibilities.................................................................................................................17
4Site construction ......................................................................................................................................... 19
4.1 About construction........................................................................................................................................ 19
4.2 Power feed....................................................................................................................................................... 19
4.3 Construct foundation.................................................................................................................................... 19
4.3.1 Placement on soil ......................................................................................................................... 19
4.3.2 Placing the ABB Standard or locally manufactured prefab concrete
foundation ..................................................................................................................................... 19
4.3.3 Instructions for a custom foundation (footprint) ................................................................20
4.4 Power cable .....................................................................................................................................................20
4.5 Internet connection .......................................................................................................................................20
5Receiving, Placing and connecting ............................................................................................................22
5.1 Receiving the cabinet.................................................................................................................................... 22
5.2 Unpacking cabinet, mounting preparations............................................................................................ 22
5.2.1 Unpacking...................................................................................................................................... 22
5.2.2 Mounting preparations............................................................................................................... 23
5.3 Move cabinet to position..............................................................................................................................24

5.3.1 Options...........................................................................................................................................24
5.3.2 Move cabinet with hoist .............................................................................................................25
5.3.3 Move cabinet forklift truck.........................................................................................................26
5.4 Mounting the cabinet....................................................................................................................................26
5.4.1 Mounting the cabinet to a foundation ....................................................................................26
5.4.2 Mounting the cabinet.................................................................................................................. 27
5.4.3 Install cable gland(s).................................................................................................................... 27
5.5 Install border covers......................................................................................................................................28
5.5.1 Install border covers of cabinet ................................................................................................28
5.6 Connect cables ...............................................................................................................................................28
5.6.1 Connect PE of power cable ........................................................................................................28
5.6.2 Connect power cable...................................................................................................................29
6Commissioning............................................................................................................................................32
6.1 Commissioning preparation........................................................................................................................32
7Cleaning of the cabinet...............................................................................................................................34
7.1 Cleaning of the cabinet.................................................................................................................................34
8Technical Data..............................................................................................................................................35
8.1 Electrical data .................................................................................................................................................35
8.2 Mechanical data..............................................................................................................................................36
8.3 Environment....................................................................................................................................................36
8.4 Certifications .................................................................................................................................................. 37
9Contact information ...................................................................................................................................38
10 Appendix A – Concrete foundation............................................................................................................39
10.1 Terra 53/54 drawing......................................................................................................................................39
11 Appendix B - Disposal instruction ............................................................................................................ 40
11.1 Directive on Waste Electrical and Electronic Equipment (WEEE – 2012/19/EU) ............................ 40

Glossary
AC
Alternating Current.
CCS
Combined Charging System. This is the name of
the charging protocol of European and North-
American car makers.
CHAdeMO
DC fast charging method for electric vehicles.
Contractor
Entity hired by the owner / site operator to do
engineering, civil and electrical installation
work.
DC
Direct Current.
EV
Electric Vehicle.
Grid provider
Company responsible for the transportation
and distribution of electricity.
HMI
Human Machine Interface; the display/screen on
the charger.
LTO
Low Temperature Option.
NOC
ABB Network Operating Centre; remotely checks
the correct 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.
RCBO
Residual-current Circuit Breaker with Overload
protection. Breaks the connection if a residual
current or overload is detected.
RCD
Residual Current Device. Breaks the connection
if a residual current is detected.
RFID
Radio-Frequency IDentification. RFID is a com-
munication technology by means of radio waves
to transfer data over a very short distance be-
tween a reader and an electronic tag or card.
Site operator
This entity is responsible for the day to day con-
trol of the charger. The site operator can be the
owner, but not necessarily.
User
The owner of an electric vehicle, who uses the
Charge Station to charge that vehicle.

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1Introduction
1.1 Preface
This guide describes the planning and physical installation of the Terra 24 or Terra 54 at
its location.
The Terra 24 and Terra 54 Charge Stations are easy to install DC fast chargers for electric
vehicles. Fast chargers are electrical installations with high electric currents. Therefore
the installation must be planned carefully, and must be done by certified personnel only
(according to local standards).
The Terra 24 is physically the same charger as a Terra 54. The main difference is the out-
put power it can deliver and therefore also the input power needed. The differences of
the Terra 24 and Terra 54, and the consequences for the installation are described in a
separate section 1.3.
As the physical installation of both types is equal, they will be referred to hereafter as
Terra 54 only and this will account for both types, unless specifically stated otherwise.
Both types come in different versions, depending on the outlet types. The different ver-
sions are described in a separate paragraph.
1.2 Intended document users
This document is intended to be used by:
•Customers who purchased a Terra 54, or are in the process of ordering and want
to know in more detail how it has to be installed.
•Contractors who are responsible for site preparation and/or installation of a
Terra 24 or Terra 54.
1.3 Similarities and differences between Terra 24 and
Terra 54
The Terra 24 and Terra 54 chargers are identical in their outer appearance and physical
dimensions. The physical installation of the Terra 24 and 54 can thus be handled the
same way.
On the inside of the cabinet there are some differences. The Terra 24 has a total of 20 kW
DC power converters where the Terra 54 has a total of 50 kW converters. The Terra 24
can be updated to a Terrra 54 in a later stadium if desired. Because of the possibility to
upgrade, we advise to dimension the grid connection cable already to the power needed
for a Terra 54, to prevent high costs for groundwork if a new cable has to be laid.
It is only possible to upgrade the DC power output of a Terra 24. The AC connector on a
T24CJG will remain 22 kW after an eventual upgrade.

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1.4 Terra version description
The Terra 24 and 54 are available in different versions depending on the available outlets.
The versions are:
Version
CCS
CCS
HV
CHAdeMO
CHAdeMO
HV
AC connector
AC
socket
T24/T54 C
X
T24/T54 CJ
X
X
T24/T54 CJG
X
X
X
T24/T54 CT
X
X
T24/T54 C HV
X
T24/T54 CJ HV
X
X
T24/T54 CJG HV
X
X
X
T24/T54 CT HV
X
X
CCCS (Combo) standard
JCHAdeMO standard
GAC connector 22/43 kW
TAC Socket 22 kW
HV High Voltage
1.5 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.
WARNING
Rotating parts
Identifies a hazard that could result in injury due to the pres-
ence of rotating or moving parts.
WARNING
Pinch Hazard
Identifies a hazard that could result in injuries, in which
some body parts are pinched or crushed.

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CAUTION
Various
Identifies a hazard that could result in damage to the ma-
chine, other equipment, and/or environmental pollution
NOTICE
Contains remarks, suggestions or advice.
1.5.1 Owner responsibilities
The owner and site operator are required:
•To operate the charge station with the protective devices installed and to make
sure all protective devices are correctly installed after carrying out installation or
maintenance.
•To write an emergency plan that instructs people what to do in case of emer-
gency.
•To prepare the site where the charge station will be installed, according to the re-
quirements described in this guide.
•To make sure that there is enough space around the charger to carry out mainte-
nance work.
•To appoint a person responsible for the safe operation of the charge station and
for the coordination of all work.
•The owner is cautioned that changes or modifications not expressly approved by
ABB could void the owner’s authority to operate the equipment and ABB’s war-
ranty policy
•Neither ABB nor its affiliates shall be liable to the purchaser of this product or
third parties for damages, losses, costs or expenses incurred by purchaser or
third parties as a result of: an accident, misuse or abuse of this product or unau-
thorized modifications, repairs or alterations to this product, or failure to strictly
comply ABB operating and maintenance instructions.
1.5.2 Tilting and handling
WARNING
Heavy equipment
The Terra 54 weighs about 350 kg. Handling Instructions:
1. Use crane, forklift or pallet truck when lifting or moving
the Terra 54.
2. Do not drop the Terra 54.
3. Do not exceed a tilting angle of 30°.
1.5.3 Sharp edges
WARNING
Sharp metal edges
There could be sharp metal edges inside the Terra 54. It is
recommended to wear mash protecting gloves when work-
ing inside the charger.

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1.5.4 Electric hazards
DANGER
Hazardous voltage
The Terra 54 contains conductors under hazardous electrical
voltages. The grid terminals on the internal DIN rail may
carry hazardous voltages, even if all circuit breakers are
switched off.
1.5.5 Installation safety
DANGER
Hazardous voltage
Instructions:
1. Always switch off the external group switch and the main
switch in the cabinet, before performing any installation, dis-
assembly, repair or replacement of components.
2. Do a voltage check and make sure that the electrical
power is disconnected from the system.
3. Only ABB certified technicians are permitted to commis-
sion the Terra.
4. When the system is in an open or dangerous condition, do
not allow unqualified persons to go near it. Instruct and
warn people about the potential harmful high voltages.
5. The installation and maintenance personnel must supply
their own lighting equipment, since the T54 has no lights in-
side the cabinet.
6. Always connect the Protective Earth (PE) first, before con-
necting the neutral (N) and Phase (P) wiring.
7. Correctly lock the door after installation or service opera-
tions.
1.6 1.6 Environment and disposal of waste
NOTICE
Always observe the local rules and regulations with respect
to processing (non-reusable) parts of the Terra 54.

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2Description 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 cable conduit (if required)
C Terra 54
D Parking space for charging
E Electric vehicle

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2.1.2 Outside view
A Door handle / lock ECharge outlet: DC connector and DC cable
B Emergency stop FAir inlet
C Display / HMI G Border cover
DRFID card reader H Air outlet (backside)
2.1.3 Inside view
A Cable gland plate D Main switch
B PE connection E Power connections
C Door switch (2x on front door, 1x on each side door)

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2.2 Geometry of infrastructure
2.2.1 Required space for placing and maintaining the Terra 54
The Terra 54 requires a space of 1585 x 1480 mm. This space is calculated as follows:
- Size Charger W x D x H: 565 x 780 x 1900 mm.
- Front side 600 mm, in order to open the front door.
- Left and right side 510 mm, in order to open left and right door.
- Backside 100 mm, in order to guarantee an unimpeded airflow.
2.2.2 Ventilation and airflow of the Terra 54
The Terra 54 has an air inlet on the right side and outlet on the back side.
NOTICE
Free air flow
If necessary, take precautions to prevent snow or objects
from blocking the in- and outlets.

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2.2.3 Bollards
It is advised to place bollards around the charger to protect the charging station against cars
hitting and damaging the cabinet.

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NOTICE
Bollards limiting the access
When installing bollards around the charger make sure all
doors can still be opened to be able to service the charger. In
case bollard are installed that are blocking the doors, make
sure they are the removable kind. The key must be available
for service engineers.
2.3 Electrical engineering
The electrical installation must be completed according to the local safety and electrical regu-
lations and laws. A one-line diagram for the electrical connections with the main safety com-
ponents inside the charger is shown in the figure below.
2.3.1 Requirements External RCD
NOTICE
External RCD not included in delivery scope
Upstream RCD’s are explicitly excluded from ABB’s delivery
scope and belong to the scope of the installation company.
The locally certified installation company can base the RCD
device type, amongst other external factors, on below
charger characteristics.
In case the local authorities prescribe the installation of an upstream RCD there are the fol-
lowing factors to take into account in selecting an RCD device of your choice.
AC-charging side prescribes Type B RCD
In case your charger is equipped with an AC charging outlet indicated by the -T or -G in the
type name, the following needs to be considered:

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•The AC charging section of the charger has a RCD type B earth leakage protection.
This protection is required to protect the person using the system from earth leak-
ages, even while the onboard charger of the connected vehicle, independent from the
charger functionality, is causing DC currents in the AC-path towards the main switch
of the charger or site distribution panel.
•Because of this Type B protection on the AC-side of the cabinet, most local installa-
tion procedures also prescribes a Type B RCD upstream if an upstream RCD is re-
quired. Your installation company is required to verify this requirement.
DC-charging side requires immunity for short current peaks over PE
When the charger engages the DC charging (at the beginning of every charger session in the
pre-charge phase) a relay switches and turns on the input to the power modules. Asynchronic
engagement of the phases in the relay in combination with the electrical capacity in the input
power part, can cause incidental very short (25 microseconds) current peaks of up to 60A
over the Protective Earth. The amplitude of the Ampere peaks can vary with the location and
is dependent on grid and earth impedance. Given the switching characteristics of the DC sec-
tion of the charger we give you the advice to select an RCD that has proven to be able to with-
stand these short current peaks (high immunity). As a suggestion to the installation company
ABB recommends the following RCD type which will work in most grid situations: (1) ABB
make F204 B S-125/0,3 code: 2CSF204823R3950. It is the responsibility of your installation
company to select the right device.
Local regulation could require a Type B upstream RCD independent of AC-charging func-
tionality
The design of the power section is such that a DC current over 6mA does NOT occur on the
AC-input side of the power section during normal operation. It is up to the local authorities to
determine if whether these fault conditions qualify as independent single fault conditions
and therefor require a Type B RCD.
CAUTION
Responsibility to comply with local regulations
The installation company is responsibly to design and install
the electrical installation according the local regulations.
2.3.2 Conductor and cable diameter
The diameter of the electrical conductor of the ground cables depends on the length, method
of installation, etc. This must be determined by your contractor.
The phases and neutral are to be mounted with cable lugs M8 (not included in delivery) on the
mains isolator. The maximum conductor surface is 95 mm2.
The maximum diameter of the (grid) cable entering the cabinet is 45 mm. The minimum di-
ameter with the standard fitted cable gland insert is 34 mm.

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Example of cable lug to be used

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3Site design
A site for EV charging can be designed in many different setups. This section is intended to
give some useful information on the placement of a charger with respect to parking spaces
and the vehicle inlets for the charging cable.
3.1 Cable reach
The charge cables of the T54 are about 3.9 meters long. The DC cables leave the charger on
the right side, the AC cable leaves on the left side. The cables and the connectors mounted on
the cables are different for each charging standard and make them more or less flexible to
reach out.
The figure below shows the charger in the center with each type of connector and how far it
can reach out. The yellow circle describes the range of the Combo cable, green circle the
CHAdeMO cable, blue circle the AC cable.
3.2 Different alignment possibilities
The charge inlets on a car can be located at different positions. The most common cars have
their inlets located either on the front of the car, or on the left or right back side.

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This makes some positions of the charger with respect to the parking space more favorable
than others. Please keep this in mind when designing a site. Some possible situations are
showed below:

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4Site construction
4.1 About construction
The construction phase includes all work required to prepare the location and make it ready
for the placement and connection of the Terra 54. The construction phase can start when:
•All preparation engineering work is done.
•All necessary permits are granted.
•The grid connection is available.
4.2 Power feed
The power cable enters the charger from below. Use foam or proper cable lugs/glands to pre-
vent the entrance of animals from the AC inlet/Ethernet cable.
4.3 Construct foundation
The correct foundation depends on the type of surface where the Terra 54 will be installed.
4.3.1 Placement on soil
There are 2 options when the charger is placed on soil:
1. Use a prefab concrete foundation to get a firm fixation on soil.
A prefab concrete foundation can be ordered separately, or produced locally accord-
ing the specifications.
2. The construction of a custom built foundation.
Depending on the situation and cable type, the cables must be embedded in the ground with
or without a cable duct. See section Cabling on Page 20.
4.3.2 Placing the ABB Standard or locally manufactured prefab concrete
foundation
1. Make a hole in the ground with a minimum of the dimensions shown.
2. Make sure the cable duct(s) are routed to one of the indicated positions (A).
3. Lower the foundation into the hole.
4. Route the cables through one of the holes (A).
A

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5. Make sure the top surface of the foundation is at least 15 mm above ground level to
prevent water from entering into the charger foundation.
6. Make sure a cable length of one meter is available above the foundation for internal
routing in the cabinet.
7. Fill the foundation with gravel or shingles to prevent rodents from entering the
equipment.
4.3.3 Instructions for a custom foundation (footprint)
1. Drill and tap 8 holes (M10) in the floor at the indicated positions (A), depth ± 60mm.
2. Make sure that the cables come out of the floor within the marked area (B).
3. Make sure that a cable length of one meter is available above the floor for internal
routing in the cabinet.
4.4 Power cable
•Cable type: 3P+N+PE, shielded cables are optional if required by local law.
•Optional cable shielding must be attached to the PE Rail at both ends of the cable.
•The diameter of the cable conductor must be determined by your contractor / elec-
trician.
•The maximum diameter surface of the cable conductor is 95 mm².
•The PE conductor of the power cable must have the same diameter as the phase con-
ductors.
•Recommended power cable: YMvKas mb 4 x 70 + 70 mm².
4.5 Internet connection
The preferred method of communication is to use the wireless 2/3G modem that is inte-
grated into the Charger. A customer SIM card is not required, a subscription for the SIM card
is provided by ABB for selected countries.
If there is no wireless signal available, a standard wired internet connection is required. This
connection must meet the following requirements: