ABB HVC-R 100 V2 User manual

—
USER MANUAL
HVC-R 100/150 V2 E-Bus Charger
User and Operation Manual for EU
products
Depot Charge Box GEN2
Version 0.1

HVC-R 100/150 V2 E-BUS CHARG ER USER GUIDE
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Notice
This document contains information about one or more ABB products and may include a de-
scription 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 fea-
tures of the described or referenced standard. In order to determine the specific features sup-
ported 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 con-
strued 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 docu-
ment.
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from ABB, and the contents thereof must not be imparted to a third party nor used for any un-
authorized purpose.
Copyrights
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owners.
Copyright © 2018 ABB.
All rights reserved.

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Table of Contents
Glossary ........................................................................................................................................................ 4
1 Introduction ............................................................................................................................................ 5
1.1 Preface ......................................................................................................................................................... 5
1.2 Intended use of this document.............................................................................................................. 5
1.3 Intended use of the charger ................................................................................................................... 5
1.4 Owner responsibilities ............................................................................................................................. 5
1.5 Signs ............................................................................................................................................................ 6
1.6 Safety regulations ..................................................................................................................................... 8
2 Description of the product .................................................................................................................... 9
2.1 Overview of the system ........................................................................................................................... 9
2.2 Charge cabinet .......................................................................................................................................... 9
2.3 Depot Charge Box GEN2 ........................................................................................................................ 10
2.4 Charger configurations .......................................................................................................................... 11
2.5 Authorization to charge.......................................................................................................................... 11
3 Charging instruction ............................................................................................................................. 12
3.1 Charging with 1 Depot Charge Box GEN2 .......................................................................................... 12
3.2 Charging with 2 or 3 Depot Charge Boxes GEN2 ............................................................................. 12
3.3 Emergency stop ...................................................................................................................................... 13
4 Operator Instructions ...........................................................................................................................14
4.1 Cleaning of the cabinet and Depot Charge Box GEN2 ................................................................... 14
4.2 Preventive maintenance ........................................................................................................................ 14
4.2.1 Service inspection of the cabinets .................................................................................... 14
4.2.2 Emergency stop inspection ................................................................................................ 15
4.2.3 Special inspections ............................................................................................................... 15
4.3 Problem resolving ................................................................................................................................... 15
4.3.1 Overview of the Power Cabinet.......................................................................................... 15
4.3.2 Overview of the Depot Charge Box GEN2 ........................................................................ 16
4.3.3 Component overview Power Cabinet ................................................................................ 17
4.3.4 Component overview Depot Charge Box GEN2 .............................................................. 17
4.4 Technical functioning ............................................................................................................................. 18
4.4.1 Normal operation .................................................................................................................. 18
4.4.2 Switch the charger system on/off..................................................................................... 18
4.4.3 Switch the Depot Charge Box GEN2 ................................................................................. 19
5 Contact information ............................................................................................................................ 20

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Glossary
1.
CCS
Combined Charging System. A universal AC
and DC charging system, also referred to as
‘Combo’.
DC
Direct Current.
EV
Electric Vehicle.
Owner
The legal owner of the charger.
OCPP
Open Charge Point Protocol. Open standard
for communication with charge stations.
PE
Protective Earth.
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 connec-
tion if a residual current is detected.
Site operator
Person or company that controls the charge
station. The site operator can be the owner,
but not necessarily.
User
The driver of an EV who uses the charge sta-
tion.

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1
Introduction
1.1 Preface
The HVC-R product line is the new ABB solution for Overnight Charging of Heavy Vehi-
cles. The product line allows 107kW and 160kW charging with up to 3 charging outlets
per one charger. The charging of the vehicles is done sequentially following the first
come, first serve principle.
This manual describes the general usage and daily operation instructions of the HVC-R
product family.
1.2 Intended use of this document
This document serves:
 As a reference for site operators who are responsible for the charger’s operation
on site, performing daily inspection and maintenance activities and who are able
to perform simple trouble shooting activities, after instruction of a certified ABB
technician.
 As a reference to the operator’s customers, the EV drivers who will mainly use
the pictograms and texts on the display of the charger. The user interface design
was thoroughly evaluated with user groups to optimize understandability and to
get the best user experience. Besides the screens needed for the charging pro-
cess, the interface has help screens available to provide additional information.
1.3 Intended use of the charger
The HVC-R product is a stand-alone DC high power charger for electric buses and trucks.
The outlets of the charger must not be used to charge any other equipment than electric
vehicles compatible with the supported charging standards.
1.4 Owner responsibilities
The owner and site operator are required:

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 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. This person should be properly instructed by
ABB or an ABB trained service partner.
The owner is cautioned that changes or modifications not expressly approved by ABB
could void the owner’s authority to operate the equipment or ABB’s warranty.
Neither ABB nor its affiliates shall be liable to the purchaser of this product or third par-
ties 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.
1.5 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.

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1.6 Safety regulations
WARNING
If a charge outlet is damaged, take the following steps:
1. Do not use the damaged charge outlet.
2. Contact the owner / site operator.
3. It is not permitted to operate the whole system if at
least one of the Depot Charge Box Boxes GEN2
shows severe malfunction. Please contact ABB Ser-
vice department for more information of error condi-
tion
WARNING
If there is an emergency
1. Push the emergency stop.
2. Contact the owner / site operator.
3. Act according to the emergency procedure of the
owner / site operator.
WARNING
Operation after damage or accidents
 If there is a fire in or nearby the charger;
 If the charger was immersed in water, or any other
fluid;
 If the charger is damaged in any way.
Do not use the charger. Contact the owner / site operator.
NOTICE
When connecting or disconnecting a connector
1. Handle cables and connectors with care. Do not drop
the cables or connectors. Place them back in their re-
spective holders.
2. Only insert a connector into a suitable car inlet.
Never use excessive force.
NOTICE
Connector locked
The DC connector will be locked during the charging process
to prevent it from dropping or being pulled out. Do not apply
a force on the cable during the charging process as it might
damage the inlet and locking mechanism in your car or dam-
age the charger.

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2 Description of the product
2.1 Overview of the system
A. Charge cabinet 100-150kW
B. Depot Charge Box Boxes GEN2 (up to 3 per charger with sequential charging)
2.2 Charge cabinet
A. Door
B. Door handle / lock
C. 3G/4G Antenna
D. Air inlets (also on the left and back side)
E. Air outlet
CAUTION
The Power Cabinet has air
inlets (D) and an air outlet (E) to control
the temperature inside the cabinet. Do not install or place any ob-
jects near or against these air inlets and outlet. If necessary, take
precautions to prevent snow or any other objects from blocking the
air inlets and outlet.

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2.3 Depot Charge Box GEN2
The user operated components are indicated on below:
A. LED beacon
B. Emergency button
C. Stop button
D. Door handle & lock
E. Connector holder
F. CCS charge cable
G. External connections
Overview LED colors and state: