ABB HVC-PD User manual

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INSTAL LATION GU IDE
HVC-PD E-Bus Charger
Installation Guide for EU products
Version 3.1

HVC-PD E-Bus Charger Installation Guide
Document: v3.1 / Document No.: 6AGA000008-0600-EN | Date: 22-05-2019 Page 2of 139
Notice
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Version control
Version
Date
Remarks
3.0
13-02-2019
First release of HVC E-Bus Charger systems based on 450 kW architecture
platform.
3.1
22-05-2019
Change the name to HVC-PD E-Bus Charger and describe only a standard
installation with pole. Improve description about placement of pole in relation with
bus. Change description of DC connection in Power Cabinet (according to Mantis
CR-11229). Added pole cover and U-profile numbers.

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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. 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 31
3.6.2. Pole position in sideways direction of the bus 32
3.6.3. Maximum slope of the road in sideways direction 34
3.6.4. Maximum slope of the road in driving direction 34
3.7. Electrical engineering 35
3.7.1. Electrical installation 35
3.8. Civil installation 35
3.9. Lightning protection 36
4. Construction 37
4.1. About construction 37

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4.2. Construct foundation of the Power Cabinet 38
4.2.1. Options 38
4.2.2. Workflow with concrete foundation 39
4.2.3. Workflow with metal frame foundation 41
4.2.4. Workflow mounting Power Cabinet direct on a floor (footprint) 42
4.3. Construct foundation of the Charge Pole 43
4.3.1. Options 43
4.3.2. Workflow with pre-fabricated concrete foundation 43
4.4. Cabling 48
4.4.1. About cabling 48
4.4.2. Charge system configurations 49
4.4.3. AC power cable 50
4.4.4. Cables between the Power Cabinets and the ACS Control Module 50
4.4.5. Cables between the Power Cabinets 51
4.4.6. Cable specification list 51
4.5. Internet connection 52
5. Placement and Connection 53
5.1. About placement and connection 53
5.2. Route the cables 54
5.3. Unpack Power Cabinet 55
5.3.1. Before unpacking 55
5.3.2. Remove packaging 56
5.4. Move Power Cabinet to position 56
5.4.1. Move cabinet with a hoist 57
5.4.2. Move cabinet with a forklift truck 58
5.5. Install Power Cabinet onto the foundation 59
5.5.1. Connect Power Cabinet to foundation 59
5.5.2. Open the door of the Power Cabinet 61
5.5.3. Move the sliding plate of the guidance plates of the cabinet 62
5.5.4. Route cables through guidance plates 62
5.5.5. Move sliding plates of the guidance plates of the cabinet 63
5.5.6. Install border covers of the Power Cabinet 64
5.5.7. Install border covers of metal frame foundation 64
5.5.8. Install front cover plate on foundation 65
5.6. Connect AC power cable and PE wires Power Cabinets 66
5.6.1. Remove the protection covers 66
5.6.2. Connect the PE wire of the AC power cable 67
5.6.3. Connect the AC power cable 68
5.6.4. Install the protection covers 69
5.6.5. Install lightning protection (optional) 70
5.6.6. Connect the PE wire to the Charge Pole 71
5.6.7. Connect the PE wire between the Power Cabinets 72
5.7. Connect the DC power cables Power Cabinets 72
5.7.1. Remove the protection cover 73
5.7.2. Connect the DC power cables 73
5.7.3. Install the protection cover 74
5.8. Connect AC utility power, Interlock and CAN cables Power Cabinet 74
5.8.1. Route the cables to the terminal blocks 74
5.8.2. Connect the AC utility power cable 75
5.8.3. Connect the Interlock cable for the HVC 150 kW system 76
5.8.4. Upgrade the Interlock connection to the HVC 300 kW system 77
5.8.5. Upgrade the Interlock connection to the HVC 450 kW system 79
5.8.6. Connect the CAN cable 81
5.9. Connect the communication cable Power Cabinet 84

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5.9.1. Route the cable to the terminal blocks 84
5.9.2. Connect the communication fiber cables 84
5.10.Close the door of the Power Cabinet 85
5.11.Unpack the Charge Pole components 86
5.11.1. Before unpacking 86
5.11.2. Remove packaging 87
5.12.Move the Charge Pole to position 87
5.13.Install vertical frame onto the foundation 88
5.14.Install horizontal frame onto the vertical frame 91
5.15.Connect PE wires to Charge Pole 93
5.15.1. Connect the PE wire of the ACS PE 94
5.15.2. Connect the PE wire from the horizontal frame 94
5.15.3. Connect the PE wire from the Junction Box 95
5.15.4. Connect the PE wire of the Power Cabinet 95
5.15.5. Install lighting protection 96
5.16.Connect cables ACS Control Module 97
5.16.1. Gland layout of the ACS Control Module 97
5.16.2. Open the door of the ACS Control Module 98
5.16.3. Connect the DC+ power in- and output cables 98
5.16.4. Connect the DC- power in- and output cables in Junction Box 100
5.16.5. Connect the AC utility power cable from Power Cabinet 102
5.16.6. Connect the communication cable from the Power Cabinet 103
5.16.7. Connect the WiFi cable 104
5.16.8. Connect the RFID cables 104
5.16.9. Connect the other cables to the ACS Control Module 106
5.17.Close the door of the ACS Control Module 108
5.18.Install masks plate work 109
5.19.Grouting of the pole construction 115
6. Commissioning 116
6.1. Commissioning preparation 116
6.2. Customer Acceptance Form (CAF) 117
7. Service and Maintenance 118
7.1. About Service and Maintenance 118
7.2. Cleaning of the cabinet 118
8. Technical Specification 119
8.1. Electrical specification complete 150 kW system 119
8.2. Electrical specification complete 300 kW system 119
8.3. Electrical specification complete 450 kW system 120
8.4. Mechanical data 120
8.5. Environment 121
8.6. Certifications 121
9. Appendix 122
A Dimensions Power Cabinet 123
B Dimensions ACS Control Module 125
C Dimensions Junction Box 126
D Dimensions Charge Pole 127
E Dimensions Concrete Foundation Power Cabinet 129
F Dimensions Metal Foundation Power Cabinet 131
G Dimensions Concrete Foundation Pole 132
H Power Cabinet –Outline with Foundation 133

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I Signal connection diagram 134
J Ground overview of the system 137
K WEEE disposal –2012-19/EU 138

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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 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-BusCharger, or are inthe processof 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.