ABB HVC-R 100 User manual

—
INSTALLATION GUIDE
HVC-R 100/150 E-Bus Charger
Installation Guide for EU products
Version 0.4

HVC-R 100/150 E-Bus Charger Installation Guide
Document: v0.4 / Document No.: TBA | Date: 11-08-2021 Page 2of 131
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
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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
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The information in this document is subject to change without notice and should not be
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appear in this document.
In no event shall ABB be liable for direct, indirect, special,incidental or consequential damages
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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
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Copyrights
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Copyright © 2021 ABB.
All rights reserved.
Version control
Version
Date
Remarks
V0
.
1
02
-
06
-
2021
Released for first review.
V0.2 11-06-2021 Altered following first review commentary.
V0.3
17
-
06
-
2021
Alterations regarding DDCB mounting and minor text editions.
V0.3.1
21
-
06
-
2021
Additional information regarding connection of multiple DDCBs.
V0.4 12-08-2021 Updated due to introduction of HVC 100/150R V2.

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Table of Contents
1. Introduction 7
1.1. Preface 7
1.2. Intended document users 7
1.3. Signs 7
1.4. Safety regulations 8
1.4.1. Owner responsibilities 8
1.4.2. Tilting and handling 9
1.4.3. Electric hazards 10
1.4.4. Installation safety 10
1.5. Environment and disposal of waste 11
1.6. Cyber Security Disclaimer 11
1.7. Contact information 12
2. Description of the product 13
2.1. Overview of the system 13
2.1.1. Standard HVC-R 100 E-Bus Charger with one Dual Depot Charge Box 13
2.1.2. Standard HVC-R 100 E-Bus Charger with two or three Dual Depot Charge Boxes 14
2.1.3. Standard HVC-R 100 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.4. Standard HVC-R 100 V2 E-Bus Charger with two or three Dual Depot Charge Boxes 14
2.1.5. Standard HVC-R 150 E-Bus Charger with one Dual Depot Charge Box 14
2.1.6. Standard HVC-R 150 E-Bus Charger with one Dual Depot Charge Box 14
2.1.7. Standard HVC-R 150 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.8. Standard HVC-R 150 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.9. HVC Power Cabinet 15
2.1.10. Dual Depot Charge Box 16
2.2. Accessories 18
2.2.1. Foundation of Power Cabinet 18
2.2.2. Pedestal of the Dual Depot Charge Box 19
2.2.3. Foundation of the pedestal 20
2.2.4. Wall-mounting brackets for Dual Depot Charge Box safe wall fixing 21
2.2.5. Communication ethernet cable 21
3. Preparation 22
3.1. Project planning 22
3.2. About preparation 23
3.3. Required permits 24
3.3.1. Power connection 24
3.3.2. Construction permit 24
3.3.3. Internet access 25
3.4. Adapting the grid 26
3.5. Location 27
3.6. Geometry of infrastructure 28
3.6.1. Space required for the Power Cabinet 28
3.6.2. Placement of multiple Power Cabinets 29
3.6.3. Space required for the Dual Depot Charge Box 30
3.7. Parking space arrangement 31
3.7.1. Cable reach 31
3.7.2. Various alignment possibilities 32
3.8. Electrical installation 33
3.9. Civil installation 34
3.10.Lightning protection 36

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4. Construction 37
4.1. About construction 37
4.2. Providing foundation for the Power Cabinet 38
4.2.1. Available options 38
4.2.2. Concrete foundation 39
4.2.3. Metal frame foundation 41
4.2.4. Mounting Power Cabinet directly on a floor 42
4.3. Mounting of the Dual Depot Charge Box 43
4.3.1. Available options 43
4.3.2. Concrete foundation for the pedestal 43
4.3.3. Wall mounting 45
4.4. Cable routing 46
4.4.1. Charge system configuration 46
4.4.2. AC power cable 47
4.4.3. Cables connecting the Power Cabinet and the Dual Depot Charge Box 47
4.4.4. Cables connecting the Dual Depot Charge Boxes 47
4.4.5. Grounding of the Dual Depot Charge Box 48
4.4.6. Optional external interface cables 49
4.4.7. Cable specification list 50
4.5. Internet connection 51
5. Placement and Connection 52
5.1. About placement and connection 52
5.2. Routing the cables 53
5.3. Unpacking Power Cabinet 54
5.3.1. Before unpacking 54
5.3.2. Remove packaging 55
5.4. Moving the Power Cabinet 56
5.4.1. Moving the Power Cabinet with a hoist 57
5.4.2. Moving the Power Cabinet with a forklift truck 58
5.5. Installing the Power Cabinet onto a foundation 59
5.5.1. Connecting Power Cabinet to a foundation 59
5.5.2. Opening the door of the Power Cabinet 61
5.5.3. Loosening the sliding plate of the guidance plates 62
5.5.4. Routing cables through the guidance plates 62
5.5.5. Tightening sliding plates of the guidance plates 63
5.5.6. Installing border covers of the Power Cabinet 64
5.5.7. Installing border covers of the metal frame foundation 65
5.5.8. Installing front cover plate on the foundation 66
5.6. Connecting AC power cables and PE wires to the Power Cabinet 67
5.6.1. Removing the protection covers 67
5.6.2. Connecting the PE wire of the AC power cables 68
5.6.3. Connecting the AC power cables 69
5.6.4. Installing the protection covers 70
5.6.5. Installing lightning protection (optional) 71
5.6.6. Attaching PE wire connecting the Dual Depot Charge Box 72
5.7. Connecting the Power Cabinet’s DC power cables 73
5.7.1. Removing the protection cover 73
5.7.2. Connecting the DC power cables 74
5.7.3. Installing the protection cover 75
5.8. Connecting Interlock cable to the Power Cabinet 76
5.9. Connecting the communication cable to the Power Cabinet 78
5.9.1. Routing the cable to the terminal blocks 78
5.9.2. Connecting the Ethernet cable to the Power Cabinet 79
5.10.Closing the door of the Power Cabinet 80

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5.11.Unpacking the Dual Depot Charge Box 81
5.11.1. Before unpacking 81
5.11.2. Removing packaging 81
5.12.Installing the Dual Depot Charge Box onto a Pedestal 82
5.12.1. Connecting the Pedestal to the Foundation 82
5.12.2. Mounting the Dual Depot Charge Box onto the Pedestal 85
5.13.Mounting the Dual Depot Charge Box onto a wall 86
5.13.1. Using the wall-mounting brackets 87
5.14.Cable connections of the Dual Depot Charge Box 89
5.14.1. Gland layout of the Dual Depot Charge Box 89
5.14.2. Opening the door of the Dual Depot Charge Box 90
5.14.3. Removing the protection cover 90
5.14.4. Connect the external PE wire 92
5.14.5. Install lighting protection (optional) 93
5.14.6. Connecting the PE or lighting protection wire onto the pedestal 94
5.14.7. Connecting the DC power in- and output cables 96
5.14.8. Connecting the AC auxiliary power cable 99
5.14.9. Connecting the InterLock cable from the Power Cabinet or the Dual Depot Charge Box 100
5.14.10. Connecting the InterLock cable to the next Dual Depot Charge Box 101
5.14.11. Connecting the communication Ethernet cable (input) 102
5.14.12. Connecting the communication Ethernet cable (output) 103
5.14.13. Connecting external EMO, Beacon and Stop button cables (optional) 104
5.14.14. Installing the protection cover 107
5.14.15. Closing the door of the Dual Depot Charge Box 108
5.14.16. Reattaching rear cover plate of the Pedestal 109
5.14.17. Reattaching front cover plate of the Pedestal 111
6. Commissioning 113
6.1. Commissioning preparation 113
6.2. Customer Acceptance Form (CAF) 114
7. Service and Maintenance 115
7.1. About Service and Maintenance 115
7.2. Cleaning of the cabinet 115
8. Technical specification 117
8.1. Electrical specification od a complete 100 kW system 117
8.2. Electrical specification of a complete 150 kW system 118
8.3. Mechanical data 118
8.4. Environment 119
8.5. Certifications 119
9. Appendices 120
A Dimensions of the Power Cabinet 121
B Dimensions of the Dual Depot Charge Box 123
C Dimensions of the Power Cabinet’s Concrete Foundation 124
D Dimensions of the Power Cabinet’s Metal Foundation 126
E Power Cabinet – Outline with the Foundation 127
F Signal connection diagram 128
G Ground overview of the system 129
H WEEE disposal – 2012-19/EU 130

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Glossary
AC
Alternating Current.
CAF
Customer Acceptance Form.
CCS (Combo)
Combined Charging System (also called
Combo) is the charging protocol for North
America and European OEMs.
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.
Owner
The legal Owner of the charger.
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.
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.

HVC-R 100/150E-Bus Charger InstallationGuide
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1. Introduction
1.1. Preface
This guide describes the planning and physical installation of the HVC-R 100/150 E-Bus
Charger at its location.
The HVC-R 100/150 E-Bus Charger is a DC fast charger system for hybrid or electrical buses
that can be used for overnight charging which is based on the CCS Charging standard. It is
not permitted to use the HVC-R 100/150 E-Bus Charger to charge any other equipment, or to
use the HVC-R 100/150 E-Bus Charger for any other purposes.
The HVC-R 100/150 E-Bus Charger uses high-amperage electric currents. Therefore, the
installation mustbe planned carefully and must be done by certified personnel only (according
to local standards1).
Before installing the HVC-R 100/150 E-Bus Charger, read this Installation Guide
carefully and attentively. Follow the instructions presented in the Installation Guide.
ABB is not responsible for any damage that could be 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 an HVC-R 100/150 E-Bus Charger or currently are in the
process of ordering and wish to know installation details.
Contractors who are responsible for site preparation and/or installation of the HVC-R
100/150 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 by
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.
1Local 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 including the cases in which
some body parts may be pinched or crushed.
WARNING
Fall Hazard
Identifies a hazard that could result in injury due to 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 special indications as well as biddings and prohibitions to avoid
damage to the environment. This sign refers to present national
regulations concerning 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 prepare a plan containing instructions on actions to be taken in case of an
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 works.
All works have to be carried out by qualified personnel.All qualified personnel have to
estimate their designated works in order to identify and avoid hazards. They must
possess experience and adequate knowledge of: safety regulations and labor medical
regulations, accident prevention regulations, guidelines and approved safety
regulations, and special instructions concerning possible occurrence of 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 borne by the Purchaser or third parties
as a result of: an accident, misuse or abuse of the product or unauthorized
modifications, repairs or alterations to the product, or failure to strictly comply to the
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.
2. Do not drop parts of the HVC-R 100/150 E-Bus Charger.
3. Do not exceed the tilting angle of 30⁰while moving or performing
works on 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
perform the work that involves lifting and tilting the equipment.
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
(refer to the guide below).
It must be carried out within the framework of an effective management system;
It must be properly planned;
Its risks have to be assessed;
Supervision must be performed over it;
It must be 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-R 100/150 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 fordamage. See sectionBeforeunpacking
on Page 54 and section Before unpacking on Page 81. If there is
damage, do not install the system.
DANGER
Hazardous voltage
Instructions:
1. Always switch off the external group switch and the main switch in
the cabinet, 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-R 100/150 E-Bus Charger.
4. When the system is in an open or dangerous state, do not allow
unqualified personnel near it. Instruct and warn people in the vicinity
about the potential harmful high voltages.
5. The installation and maintenance personnel must be supplied with
their own lighting equipment, since the HVC-R 100/150 E-Bus
Charger has no lights inside the cabinet.
6. Always connect the ProtectiveEarth (PE) first,before connecting the
neutral (N) and Phase (P) wiring.
7. Correctly lock the door after completing installation or service
operations.
WARNING
Make sure that there is a minimum free space of 1000 mm 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 in case
of an emergency while the door remains open.