ABB HVC-PD User manual

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INSTALLATION GUIDE
HVC-PD E-Bus Charger
Installation Guide for NA products
Version 1.2

HVC‐PDE‐BusChargerInstallationGuide
Document: V1.2 / Document No.: 6AGA000008-0629-EN | Date: 06-30-2022 Page 2of 146
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Notice
This document contains information about one or more ABB products and may include a
description 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 representation that all of the ABB products referenced in this document support all of
the features of the described or referenced standard. In order to determine the specific
features supported by a particular ABB product, the reader should consult the product
specifications for the particular ABB product.
ABB may have one or more patents or pending patent applications protecting the intellectual
property in the ABB products described in this document.
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that may
appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages
of any nature or kind arising from the use of this document, nor shall ABB be liable for
incidental or consequential damages arising from use of any software or hardware described
in this document.
This document is originally written in English. Other language versions are a translation of the
original document and ABB cannot be held liable for errors in the translation.
This document and parts thereof must not be reproduced or copied without written permission
from ABB, and the contents there of must not be imparted to a third party nor used for any
unauthorized purpose.
Copyrights
All rights to copyrights, registered trademarks, and trademarks reside with their respective
owners.
Copyright © 2020 ABB.
All rights reserved.

HVC‐PDE‐BusChargerInstallationGuide
Document: V1.2 / Document No.: 6AGA000008-0629-EN | Date: 06-30-2022 Page 3of 146
Version control
Version Date Remarks
1.0 20-5-20201 First release
1.1 23-09-2021 Changed figures cabinet and added notice for WiFi device
1.2 30-06-2022 Updated based on NA requirements

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Table of Contents
1. Introduction 9
1.1. Preface 9
1.2. Intended document users 9
1.3. Signs 9
1.4. Safety regulations 10
1.4.1. Owner responsibilities 10
1.4.2. Tilting and handling 11
1.4.3. Electric hazards 12
1.4.4. Installation safety 12
1.5. Environment and disposal of waste 13
1.6. Cyber Security Disclaimer 13
1.7. Contact information 14
2. Description of the product 15
2.1. Overview of the system 15
2.1.1. Standard HVC-PD 150 kW E-Bus Charger system 15
2.1.2. Standard HVC-PD 300 kW E-Bus Charger system 16
2.1.3. Standard HVC-PD 450 kW E-Bus Charger system 16
2.1.4. Power Cabinet 17
2.1.5. ACS Control Module 18
2.1.6. Junction Box 19
2.1.7. Charge pole 19
2.2. Accessories 20
2.2.1. Foundation for Power Cabinet 20
2.2.2. Foundation for Charge pole construction 21
2.2.3. Communication glass fiber cable 22
2.2.4. RFID unit 23
2.3. Project planning 24
3. Preparation 25
3.1. About preparation 25
3.2. Permits 26
3.2.1. Power connection 26
3.2.2. Construction permit 26
3.2.3. Internet access 26
3.3. Upgrade grid 27
3.4. Location 27
3.5. Geometry of infrastructure 28
3.5.1. Required space for the Power Cabinet 28
3.5.2. Placement of multiple cabinets 29
3.5.3. Required space for the Charge pole 30
3.6. Pole position in relation to the bus 31
3.6.1. Pole position in relation to the drive direction of the bus 32
3.6.2. Pole position in sideways direction of the bus 32
3.6.3. Maximum slope of the road in X-axis 34
3.6.4. Maximum slope of the road in Z-axis 35
3.7. Electrical engineering 36
3.7.1. Electrical installation 36
3.8. Civil installation 36
3.9. Lightning protection 37
4. Construction 38

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4.1. About construction 38
4.2. Construct foundation of the Power Cabinet 39
4.2.1. Options 39
4.2.2. Workflow with concrete foundation 40
4.2.3. Workflow with metal frame foundation 42
4.2.3.1. HPC175-HVC150 MET FOUND KIN 8IN – NAM (2CEB489802R0001) 42
4.2.4. Workflow mounting Power Cabinet direct on a floor (footprint) 43
4.3. Construct foundation of the Charge pole (for reference only) 44
4.3.1. Options 44
4.3.2. Workflow with pre-fabricated concrete foundation (for reference only) 44
4.4. Cabling 49
4.4.1. Charge system configuration 49
4.4.2. AC power cable 51
4.4.3. Cables between the Power Cabinets and the ACS Control Module 51
4.4.4. Cables between the Power Cabinets 51
4.4.5. Cable specification list 52
4.5. Internet connection 53
5. Placement and Connection 54
5.1. About placement and connection 54
5.2. Route the cables 55
5.3. Unpack Power Cabinet 55
5.3.1. Before unpacking 55
5.3.2. Remove packaging 57
5.4. Move Power Cabinet to position 57
5.4.1. Move cabinet with a hoist 58
5.4.2. Move cabinet with a forklift truck 59
5.5. Install Power Cabinet onto the foundation 60
5.5.1. Connect Power Cabinet to foundation 60
5.5.2. Open the door of the Power Cabinet 62
5.5.3. Move the sliding plate of the guidance plates of the cabinet 63
5.5.4. Route cables through guidance plates 63
5.5.5. Move sliding plates of the guidance plates of the cabinet 64
5.5.6. Install border covers of the Power Cabinet 65
5.5.7. Install border covers of metal frame foundation 65
5.6. Connect AC power cable and GND wires Power Cabinets 66
5.6.1. Remove the protection covers 66
5.6.2. Connect the GND wire of the AC power cable 67
5.6.3. Connect the AC power cable 68
5.6.4. Install the protection covers 70
5.6.5. Install lightning protection (optional) 71
5.6.6. Connect the GND wire to the Charge pole 72
5.6.7. Connect the GND wire between the Power Cabinets 73
5.7. Connect the DC power cables Power Cabinets 73
5.7.1. Connect the DC power cables 74
5.7.2. Install the protection cover 75
5.8. Connect AC utility power, Interlock and CAN cables Power Cabinet 75
5.8.1. Route the cables to the terminal blocks 75
5.8.2. Connect the AC utility power cable 76
5.8.3. Connect the Interlock cable for the HVC 150 kW system 77
5.8.4. Upgrade the Interlock connection to the HVC 300 kW system 78
5.8.5. Upgrade the Interlock connection to the HVC 450 kW system 80
5.8.6. Connect the CAN cable 82
5.9. Connect the communication cable Power Cabinet 85
5.9.1. Route the cable to the terminal blocks 85

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5.9.2. Connect the communication fiber cables 85
5.10. Close the door of the Power Cabinet 86
5.11. Unpack the Charge Pole 87
5.11.1. Before unpacking 87
5.11.2. Remove packaging 88
5.12. Move the Charge pole to position 88
5.13. Install Charge Pole onto the foundation 90
5.14. Install mast boom onto column 92
5.15. Pantograph adjustment 97
5.15.1. Instruction for pantograph adjustment and alignment 97
5.15.2. Pantograph setting range adjustment 100
5.15.3. Pantograph Z-axis angle adjustment 102
5.15.4. Pantograph X-axis angel adjustment 103
5.16. Installation of the cables inside Charge Post 103
5.16.1. Open the door and remove cover plate 103
5.16.2. Connect GND wires of the Power Cabinet 105
5.16.3. Install lightning protection 105
5.16.4. Gland layout of the ACS Control Module 106
5.16.5. Open the door of the ACS Control Module 107
5.16.6. Connect the DC+ power input cables 107
5.16.7. Connect the DC- power input cables in Junction Box 109
5.16.8. Connect the AC utility power cable from Power Cabinet 111
5.16.9. Connect the communication cable from the Power Cabinet 112
5.16.10. Connect the WiFi cable 112
5.16.11. Connect the RFID cables 113
5.16.12. Connect the Interlock cable from the Power Cabinet 114
5.16.13. Connect the other cables to the ACS Control Module 115
5.16.14. Close the door of the ACS Control Module 118
5.16.15. Place back cover plate and close door of the Charge Pole 118
5.17. Install cover plates 119
5.18. Grouting of the pole construction 120
6. Commissioning 121
6.1. Commissioning preparation 121
6.2. Customer Acceptance Form (CAF) 122
7. Service and Maintenance 123
7.1. About Service and Maintenance 123
7.2. Cleaning of the cabinet 123
8. Technical Specification 125
8.1. Electrical specification complete 150 kW system 125
8.2. Electrical specification complete 300 kW system 125
8.3. Electrical specification complete 450 kW system 126
8.4. Mechanical data 126
8.5. Environment 127
8.6. Certifications 127
9. Appendix 128
A. Dimensions Powe 129
B. Dimensions ACS Control Module 131

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C. Dimensions Junction Box 132
D. Dimensions Charge pole 133
E. Clearance and vertical working range of the pantograph 135
F. Dimensions Concrete Foundation Power Cabinet 136
G. Dimensions Metal Foundation Power Cabinet 138
H. Dimensions Concrete Foundation Pole 140
I. Power Cabinet – Outline with Foundation 141
J. Signal 142
K. Ground overview of the system 145

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Glossary
AC
Alternating Current.
ACM
ACS Control Module
ACS
Automatic Control System. In this charger
system the pantograph.
CAF
Customer Acceptance Form.
Contractor
Entity hired by the owner / site operator to
do engineering, civil and electrical
installation work.
DC
Direct Current.
Grid provider
Company responsible for the
transportation and distribution of electricity.
HMI
Human Machine Interface; the screen on
the charger.
HVC
Heavy Vehicle Charger.
Power Cabinet
Intermediate unit that provides 150 kW of
DC power to the Charge control set. Gets
its power from a power distribution board.
Interlock
The Interlock is an isolated current loop
and is a feature that makes the state of two
mechanisms or functions mutually
dependent.
LAN
A computer network that interconnects
computers systems within a limited area.
NOC
ABB Network Operating Centre; remotely
checks the correct functioning of the
charger.
OPP Charge
Is a trade name of fast charging method for
electric vehicles.
Owner
The legal owner of the charger.
Pantograph
The mechanical contact linkage of the
charger through which the DC charge
power is electrical transported to the
electrical vehicle.
PD
Panto Down. A charge system where the
pantograph is mounted external from the
vehicle.
PE
Protective Earth.
PPE
Personal Protective Equipment. Equipment
such as safety shoes, helmet, glasses,
gloves.
RCD
Residual-Current Device.
RFID
Radio-Frequency IDentification. RFID is a
communication technology by means of
radio waves to transfer data over a very
short distance between a reader and an
electronic tag or card.
Site operator
The entity is responsible for the day to day
control of the charger. The site operator
can be the owner, but not necessarily.
TOR
Top of Road
User
The owner of an electric vehicle, who uses
the Charge Station to charge that vehicle.
WiFi
A technology that allows electronic devices
to connect to a wireless LAN (WLAN)
network.

1. Introduction
1.1. Preface
This guide describes the planning and physical installation of the HVC-PD E-Bus Charger with
a “fold-out” charge Pole at its location.
The HVC-PD E-Bus Charger is a DC fast charger system for hybrid or electrical buses that
are compatible with the OPP Charging standard
1
. It is not permitted to use the HVC-PD E-Bus
Charger to charge any other equipment, or to use the HVC-PD E-Bus Charger for any other
purposes.
The HVC-PD E-Bus Charger uses high-amperage electric currents. Therefore the installation
must be planned carefully, and must be done by certified personnel only (according to local
standards
2
).
Before installing the HVC-PD E-Bus Charger, read this Installation Guide carefully and
attentively. Follow the instructions in this Installation Guide. ABB is not responsible for
any damage that has been caused by not or incorrectly following and executing the
instruction described in this manual.
1.2. Intended document users
This document is intended to be used by:
Customers who purchased a HVC-PD E-Bus Charger, 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 the HVC-PD
E-Bus Charger.
1.3. 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 presence of
rotating or moving parts.
1
More information on OPP Charge via www.oppcharge.org.
2
Local regulations shall take precedence if they list different installation requirements than prescribed in this Installation
Manual.

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WARNING
Pinch Hazard
Identifies a hazard that could result in injuries in which some body parts
are pinched or crushed.
WARNING
Fall Hazard
Identifies a hazard that could result in injury due unsafe work at height.
CAUTION
Various
Identifies a hazard that could result in damage to the machine, other
equipment, and/or environmental pollution.
CAUTION
Environmental damage
Identifies a special indications as well as biddings and prohibitions to
avoid damages in the environment. This sign refer to present national
regulation according the environment.
NOTICE
Contains remarks, suggestions or advice.
1.4. Safety regulations
1.4.1. 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 emergency.
To prepare the site where the charge station will be installed, according to the
requirements described in this guide.
To make sure that there is enough space around the charger to carry out maintenance
work.
To appoint a person responsible for the safe operation of the charge station and for
the coordination of all work.
All works have to be carried out from qualified personnel. All qualified personnel has
to estimate their transmitted works, identify and avoid. They must have experience and
enough knowledge over: safety regulations and labor medical regulations, accident
prevention regulations, guideline and approved safety regulations, and special
instruction concerning occurrence of danger (especially remaining risk) possible
dangers.