ABB HVC-R 100/150 V2 User manual

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INSTALLATION GUIDE
HVC-R 100/150 V2 E-Bus Charger
Installation Guide for EU products
Version 0.1

HVC-R 100/150 V2E-Bus Charger Installation Guide
Document: v0.1 / Document No.: TBA | Date: XX-08-2021 Page2of 133
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Copyright © 2021 ABB.
All rights reserved.
Version control
Version
Date
Remarks
V0
.
1
30
-
0
8
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2021
Released for first review.

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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 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.2. Standard HVC-R 100 V2 E-Bus Charger with two or three Dual Depot Charge Boxes 14
2.1.3. Standard HVC-R 150 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.4. Standard HVC-R 150 V2 E-Bus Charger with one Dual Depot Charge Box 14
2.1.5. HVC Power Cabinet 15
2.1.6. 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 35
3.10.Lightning protection 37
4. Construction 38
4.1. About construction 38
4.2. Providing foundation for the Power Cabinet 39
4.2.1. Available options 39

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4.2.2. Concrete foundation 40
4.2.3. Metal frame foundation 42
4.2.4. Mounting Power Cabinet directly on a floor 43
4.3. Mounting of the Dual Depot Charge Box 44
4.3.1. Available options 44
4.3.2. Concrete foundation for the pedestal 44
4.3.3. Wall mounting 46
4.4. Cable routing 47
4.4.1. Charge system configuration 47
4.4.2. AC power cable 49
4.4.3. Cables connecting the Power Cabinet and the Dual Depot Charge Box 49
4.4.4. Cables connecting the Dual Depot Charge Boxes 49
4.4.5. Grounding of the Dual Depot Charge Box 50
4.4.6. Optional external interface cables 51
4.4.7. Cable specification list 52
4.5. Internet connection 53
5. Placement and Connection 54
5.1. About placement and connection 54
5.2. Routing the cables 55
5.3. Unpacking Power Cabinet 56
5.3.1. Before unpacking 56
5.3.2. Remove packaging 57
5.4. Moving the Power Cabinet 58
5.4.1. Moving the Power Cabinet with a hoist 59
5.4.2. Moving the Power Cabinet with a forklift truck 60
5.5. Installing the Power Cabinet onto a foundation 61
5.5.1. Connecting Power Cabinet to a foundation 61
5.5.2. Opening the door of the Power Cabinet 63
5.5.3. Loosening the sliding plate of the guidance plates 64
5.5.4. Routing cables through the guidance plates 64
5.5.5. Tightening sliding plates of the guidance plates 65
5.5.6. Installing border covers of the Power Cabinet 66
5.5.7. Installing border covers of the metal frame foundation 67
5.5.8. Installing front cover plate on the foundation 68
5.6. Connecting AC power cables and PE wires to the Power Cabinet 69
5.6.1. Removing the protection covers 69
5.6.2. Connecting the PE wire of the AC power cables 70
5.6.3. Connecting the AC power cables 71
5.6.4. Installing the protection covers 72
5.6.5. Installing lightning protection (optional) 73
5.6.6. Attaching PE wire connecting the Dual Depot Charge Box 74
5.7. Connecting the Power Cabinet’s DC power cables 75
5.7.1. Removing the protection cover 75
5.7.2. Connecting the DC power cables 76
5.7.3. Installing the protection cover 77
5.8. Connecting Interlock cable to the Power Cabinet 78
5.9. Connecting the communication cable to the Power Cabinet 80
5.9.1. Routing the cable to the terminal blocks 80
5.9.2. Connecting the Ethernet cable to the Power Cabinet 81
5.10.Closing the door of the Power Cabinet 82
5.11.Unpacking the Dual Depot Charge Box 83
5.11.1. Before unpacking 83
5.11.2. Removing packaging 83
5.12.Installing the Dual Depot Charge Box onto a Pedestal 84

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5.12.1. Connecting the Pedestal to the Foundation 84
5.12.2. Mounting the Dual Depot Charge Box onto the Pedestal 87
5.13.Mounting the Dual Depot Charge Box onto a wall 88
5.13.1. Using the wall-mounting brackets 89
5.14.Cable connections of the Dual Depot Charge Box 91
5.14.1. Gland layout of the Dual Depot Charge Box 91
5.14.2. Opening the door of the Dual Depot Charge Box 92
5.14.3. Removing the protection cover 92
5.14.4. Connect the external PE wire 94
5.14.5. Install lighting protection (optional) 95
5.14.6. Connecting the PE or lighting protection wire onto the pedestal 96
5.14.7. Connecting the DC power in- and output cables 98
5.14.8. Connecting the AC auxiliary power cable 101
5.14.9. Connecting the InterLock cable from the Power Cabinet or the Dual Depot Charge Box 102
5.14.10. Connecting the InterLock cable to the next Dual Depot Charge Box 103
5.14.11. Connecting the communication Ethernet cable (input) 104
5.14.12. Connecting the communication Ethernet cable (output) 105
5.14.13. Connecting external EMO, Beacon and Stop button cables (optional) 106
5.14.14. Installing the protection cover 109
5.14.15. Closing the door of the Dual Depot Charge Box 110
5.14.16. Reattaching rear cover plate of the Pedestal 111
5.14.17. Reattaching front cover plate of the Pedestal 113
6. Commissioning 115
6.1. Commissioning preparation 115
6.2. Customer Acceptance Form (CAF) 116
7. Service and Maintenance 117
7.1. About Service and Maintenance 117
7.2. Cleaning of the cabinet 117
8. Technical specification 119
8.1. Electrical specification od a complete 107 kW system 119
8.2. Electrical specification of a complete 160 kW system 120
8.3. Mechanical data 120
8.4. Environment 121
8.5. Certifications 121
9. Appendices 122
A Dimensions of the Power Cabinet 123
B Dimensions of the Dual Depot Charge Box 125
C Dimensions of the Power Cabinet’s Concrete Foundation 126
D Dimensions of the Power Cabinet’s Metal Foundation 128
E Power Cabinet – Outline with the Foundation 129
F Signal connection diagram 130
G Ground overview of the system 131
H WEEE disposal – 2012-19/EU 132

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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 distributionof 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
PersonalProtective 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.

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1. Introduction
1.1. Preface
This guide describes the planning and physical installation of the HVC-R 100/150 V2 E-Bus
Charger at its location.
The HVC-R 100/150 V2 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 V2 E-Bus Charger to charge any other
equipment, or to use the HVC-R 100/150 V2 E-Bus Charger for any other purposes.
The HVC-R 100/150 V2 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 standards1).
Before installing the HVC-R 100/150 V2 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 V2 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 V2 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 andprohibitions 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 V2 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 V2 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 section Beforeunpacking
on Page 56 and section Before unpacking on Page 83. 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 V2 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 V2 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 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.