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
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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.

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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.

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You are not allowed to modify the charge system without the permission of ABB. 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 warranty 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 unauthorized
modifications, repairs or alterations to this product, or failure to strictly comply ABB
operating and maintenance instructions.
1.4.2. Tilting and handling
CAUTION
Heavy equipment
Handling instructions:
1. Use crane or forklift truck when lifting or moving the Power Cabinet
and pole construction.
2. Do not drop parts of the HVC-PD E-Bus Charger.
3. Do not exceed a tilting of 30⁰for the Power Cabinet.
4. Read and follow the ABB Guidance on the requirements for safe
operation of mobile cranes (ML-03, 9Akk104941D0113).
WARNING
Personal safety (PPE)
Always wear a safety helmet, safety gloves and safety shoes when you
do the lifting and tilting work.
WARNING
Make sure that personnel cannot be crushed or become trapped during
lifting and tilting work.
Lifting activities
It is a legal requirement that all activities involving lifting equipment are planned and that they
are conducted under effective supervision and managed based on the risk, complexity of the
activity and the work environment (EU directive 2009/104/EEG, appendix II, chapter 3.2.5).
It is of great importance, regardless of location, that any lifting activity is performed safely,
because the activity:
Carry out within the framework of an effective management system;
Properly planned;
Risk has been assessed;
Supervision is being held; and
Performed by skilled personnel and with the appropriate means.
All lifting activities must be performed under the ABB Guidance on the requirements for safe
operation of mobile cranes (ML-03, 9Akk104941D0113).
When applying this Standard, local laws and regulations must be taken into account at all
times. In the event of conflicts, local laws and regulations prevail over this Standard.

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1.4.3. Electric hazards
DANGER
Hazardous voltage
The HVC-PD E-Bus Charger 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.
1.4.4. Installation safety
WARNING
Personal safety (PPE)
Always wear a safety helmet, safety gloves and safety shoes when you
do the lifting and tilting work.
WARNING
Visually examine the package for damage. See section Before unpacking
on Page 55 and section Before unpacking on Page 87. If there is
damage, do not install the system.
DANGER
Hazardous voltage
Instructions:
1. Always switch off the external group switch before performing any
installation, disassembly, 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 commission the
HVC-PD E-Bus Charger.
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 HVC-PD E-Bus Charger has no lights
inside the cabinet.
6. Always connect the Protective Earth (PE) first, before connecting the
neutral (N) and Phase (P) wiring.
7. Correctly lock the door after installation or service operations.
WARNING
Make sure that there is a minimum free space of 39.37 Inch in front of
the door of the Power Cabinet. The minimum space is necessary to allow
service personnel to quickly move away from the Power Cabinet if there
is an emergency when the door is open.

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WARNING
Make sure that there is a minimum free space of 39.37 Inch in front of
the door of the ACS Control Module. The minimum space is necessary
to allow service personnel to quickly move away from the ACS Control
Module if there is an emergency when the door is open.
CAUTION
Warranty
Installation and commissioning work must be carried out by certified
personnel. The warranty will be void if any work carried out by non-
certified personnel.
Un-authorized modifications of hardware will void units warranty and
service support.
1.5. Environment and disposal of waste
CAUTION
Always observe the local rules and regulations with respect to processing
(non-reusable) parts of the HVC-PD E-Bus Charger.
1.6. Cyber Security Disclaimer
This product is designed to be connected to and to communicate information and data via a
network interface. It is customer's sole responsibility to provide and continuously ensure a
secure connection between the product and customer network or any other network (as the
case may be). Customer shall establish and maintain any appropriate measures (such as but
not limited to the installation of firewalls, application of authentication measures, encryption of
data, installation of anti-virus programs, etc) to protect 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.
ABB Ltd 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.

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1.7. Contact information
ABB in your country
Please contact ABB in your country for sales, delivery and service information.
ABB EV Infrastructure global
ABB EV Infrastructure
Address Heertjeslaan 6
2629 JG Delft
The Netherlands
Telephone [phone]
Mail [email protected]
Write down here your local ABB contact details:

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2. Description of the product
2.1. Overview of the system
Example of a complete installation
A Low voltage power distribution cabinet of the owner
B Input power cables in cable conduit
C Power Cabinet – 450 kW (HVC 150 + 2x HVC 150S)
D Cables between Power Cabinet and charge pole in cable conduits
E Charge Pole with ACM and ACS
F Bus stop space for Opportunity Charging (OPP Charge)
G Electric hybrid and/or full electric Bus
The HVC-PD E-Bus Charger consists out of multiple components and it may require additional
parts depending on the project and location of installation which dictates whether these parts
are needed.
ABB offers a standard delivery system configurations with a DC charge power of 150, 300 or
450 kW.
Additional needed components can be ordered separately and are not part of the standard
delivery. See section Accessories on Page 20.
2.1.1. Standard HVC-PD 150 kW E-Bus Charger system
The following parts are provided for this system configuration:
1x HVC Panto Down 150 kW primary power cabinet
1x fold-out HVC PD charge pole set 150-450kW UL (ABB6AGC100126) or HVC PD
charge pole set 150-450kW UL BAA (ABB6AGC100125) including:
1x ACS Control Module (ACM)
1x Pantograph (ACS)
1x Charge state indicator lights with light-sensor
1x Emergency unit
1x WiFi communication unit (for the bus)
Pre-mounted cable set for inside the pole
Transport and lifting tools

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2.1.2. Standard HVC-PD 300 kW E-Bus Charger system
The following parts are provided for this system configuration:
HVC Panto Down 300 kW set of power cabinets:
1x HVC Panto Down 150 kW primary power cabinet
1x HVC Panto Down 150 kW secondary power cabinet 1x fold-out HVC PD charge
pole set 150-450kW UL (ABB6AGC100126) or HVC PD charge pole set 150-450kW
UL BAA (ABB6AGC100125) including:
1x ACS Control Module (ACM)
1x Pantograph (ACS)
1x Charge state indicator lights with light-sensor
1x Emergency unit
1x WiFi communication unit (for the bus)
Pre-mounted cable set for inside the pole
Transport and lifting tools
2.1.3. Standard HVC-PD 450 kW E-Bus Charger system
The following parts are provided for this system configuration:
1x HVC Panto Down 150 kW primary power cabinet
1x fold-out HVC PD charge pole set 150-450kW UL (ABB6AGC100126) or HVC PD
charge pole set 150-450kW UL BAA (ABB6AGC100125) including:
1x ACS Control Module (ACM)
1x Pantograph (ACS)
1x Charge state indicator lights with light-sensor
1x Emergency unit
1x WiFi communication unit (for the bus)
Pre-mounted cable set for inside the pole
Transport and lifting tools
NOTICE
The cables between the Power Cabinet(s) and Charge Pole is not part of
the order. See section Cabling on Page 49 for selecting the right cable
type needed between the Power Cabinet(s) and Charge Pole.

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2.1.4. Power Cabinet
Outside view of the Power Cabinet
A Base cover D 3G Antenna
B Air outlet E Air inlets (also on the left and back side)
C Door F Door handle / lock
Inside view of the Power Cabinet
A AC Fuses D Data/communication connection
B AC Power connection E Display (only present in HVC 150)
C Guidance plate of the cables

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2.1.5. ACS Control Module
Outside view of the ACS Control Module
A Door
B Locks
C WiFi coax connector
D In- and outputs for cables from Power Cabinet and to pantograph
E In- and outputs DC power cables
Inside view of the ACS Control Module
A Communication connection
B Connection block
C Protection cover for DC contactors

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2.1.6. Junction Box
Outside view Junction Box
A Cover
B In- and outputs DC power cables
C Output DC- OVP sensing cable
2.1.7. Charge pole
Outside view Charge pole
A Door
B Emergency button (EMO)
C Charge state indicator light with light sensor (beacon)
D Pantograph (installation specific)
E WiFi communication unit
F RFID unit (optional)

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View of the pantograph
A Base frame
B Lower arm
C Lower guide rod
D Upper arm
E Collector head guidance
F Tension spring
G Collector head
2.2. Accessories
The following parts can be ordered at the time of the initial order or afterwards. Contact ABB
Sales department (see Contact information on Page 14 for contact details).
2.2.1. Foundation for Power Cabinet (for reference only)
Concrete foundation
NOTICE
Concrete foundations for power cabinet are not sold in NA. Designs are
available in Appendix E and must be manufactured by installer, not
manufactured by ABB.
A Foundation
B Top cover plate
C Front cover plate