ABB HVC-R 107 V2 User manual

—
EV CHARGING INFRASTRUCTURE
User Manual (EU version)
HVC-R 107/160 V2 E-Bus Charger
Depot Box GEN2

HVC-R 107/160 V2 E-BUS CHARGER - USER MANUAL
DOCUMENT: V0.3 / DOCUMENT NO.: 9AKK108467A6635-EN | DATE: 20-12-2022 Page 2of 20
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 the ABB products referenced in this document support all the features of the described or refer-
enced 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 conse-
quential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without written permission from
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Copyrights
All rights to copyrights, registered trademarks, and trademarks reside with their respective own-
ers.
Copyright © 2022 ABB.
All rights reserved.
Version control
Version
Date
Remarks
V0.1
06/02/2022
First draft
V0.2
07/12/2022
Updated cover page and layout of the document. Added “version control” table
V0.3
20/12/2022
N
ame of the products from “HVC-R 100/150 V2 E-Bus Charger” to “HVC-R 107/160
V2 E-Bus Charger” . Number of connectable Depot from 3 to 4

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Table of Contents
Glossary........................................................................................................................................................ 4
1Introduction ............................................................................................................................................. 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 ................................................................................................................................ 6
1.5 Signs............................................................................................................................................................. 6
1.6 Safety regulations ....................................................................................................................................... 7
2Description of the product ..................................................................................................................... 8
2.1 Overview of the system.............................................................................................................................. 8
2.2 Charge cabinet............................................................................................................................................ 8
2.3 Depot Charge Box GEN2 .......................................................................................................................... 9
2.4 Charger configurations............................................................................................................................. 10
2.5 Authorization to charge ............................................................................................................................ 10
3Charging instruction .............................................................................................................................10
3.1 Charging with 1 Depot Charge Box GEN2............................................................................................ 10
3.2 Charging with 2, 3 or 4 Depot Charge Boxes GEN2 ............................................................................11
3.3 Emergency stop ........................................................................................................................................ 12
4Operator Instructions ............................................................................................................................13
4.1 Cleaning of the cabinet and Depot Charge Box GEN2 ....................................................................... 13
4.2 Preventive maintenance .......................................................................................................................... 13
4.2.1 Service inspection of the cabinets ........................................................................................ 13
4.2.2 Emergency stop inspection.................................................................................................... 14
4.2.3 Special inspections ................................................................................................................. 14
4.3 Problem resolving ..................................................................................................................................... 14
4.3.1 Overview of the Power Cabinet............................................................................................. 14
4.3.2 Overview of the Depot Charge Box GEN2 .......................................................................... 15
4.3.3 Component overview Power Cabinet................................................................................... 15
4.3.4 Component overview Depot Charge Box GEN2 ................................................................ 16
4.4 Technical functioning ................................................................................................................................ 16
4.4.1 Normal operation..................................................................................................................... 16
4.4.2 Switch the charger system on/off.......................................................................................... 16
4.4.3 Switch the Depot Charge Box GEN2 ....................................................................................17
5Contact information...............................................................................................................................18

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Glossary
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 connection
if a residual current is detected.
Site operator
Person or company that controls the charge sta-
tion. The site operator can be the owner, but not
necessarily.
User
The driver of an EV who uses the charge station.

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1 Introduction
1.1 Preface
The HVC-R product line is the new ABB solution for Overnight Charging of Heavy Vehicles. The prod-
uct line allows 107kW and 160kW charging with up to 3 charging outlets per one charger. The charg-
ing of the vehicles is done sequentially following the first come, first serve principle.
A. First Bus 1starts charging with 160kW full power, using Depot box 1. When bus 1is full it
stops charging.
B. Then Bus 2charges with 160kW until full using Depot box 2. Charging stops.
C. Then Bus 3charges with 160kW until full using Depot box 3. Charging stops.
D. Finally Bus 4charges with 160kW until full using Depot box 4. Charging stops.
This manual describes the general usage and daily operation instructions of the HVC-R product fam-
ily.
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, per-
forming daily inspection and maintenance activities and who are able to perform simple trou-
ble 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 process, the interface has help screens available to pro-
vide 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.

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1.4 Owner responsibilities
The owner and site operator are required:
•To operate the charge station with the protective devices installed, and to make sure all pro-
tective 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 coor-
dination of all work. This person should be properly instructed by ABB or an ABB trained ser-
vice 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 parties for dam-
ages, losses, costs or expenses incurred by purchaser or third parties as a result of: an accident, mis-
use 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 presence
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 machine,
other equipment, and/or environmental pollution
NOTICE
Contains remarks, suggestions or advice.
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 Service department for
more information of error condition
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 respective
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 damage the charger.

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2 Description of the product
2.1 Overview of the system
A. Charge cabinet 107-160kW
B. Depot Charge Box Boxes GEN2 (up to 4 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 objects 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:

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2.4 Charger configurations
The charger is built up with a modular architecture.
Supported charging standards in a charger configuration are described by a letter:
Product
Description
HVC-107R V2 CE
107kW charge cabinet configuration with 1 to 4 Depot Charge Box
Boxes GEN2, supporting CCS2 with CE certification
HVC-160R V2 CE
160kW charge cabinet configuration with 1to 4 Depot Charge Box
Boxes GEN2, supporting CCS2 with CE certification
For each product configuration (107 or 160kW) it is possible to connect 1 up to 4 Depot Charge Box
Boxes GEN2.
2.5 Authorization to charge
The standard setting is without authorization. This means that every vehicle supporting CCS is able
and allowed to start a charge session. Operating a charger with authorization requires a subscription
to a back office. Authorization can only be done based on the Vehicle ID and requires a subscription
to a back office. This product does not support a RFID reader.
3 Charging instruction
3.1 Charging with 1 Depot Charge Box GEN2
Start charging:
1. Park the electric vehicle with the charge inlet within reach of the connector.
2. Turn off the electric vehicle.
3. Connect the charger’s connector to the vehicle’s charge inlet.

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4. The charger will automatically start to charge the vehicle after the preparation phase, and will
indicate the progress by the LED state (see in figure 3).
Stop charging:
5. The charge session will automatically stop after completing the bulk charge mode (standard
setting is 99% SOC for this setup but this can be customized).
6. The charge session can also be stopped manually by either pushing the stop button on the
Depot Charge Box GEN2 or the stop button on the bus (not available on every bus).
7. Charging stops
8. The connector is unlocked by the vehicle for CCS when the Depot Charge Box GEN2 beacon
light changes color to green
9. Take the connector out of the vehicle and put it back in the connector holder on the Depot
Charge Box GEN2.
3.2 Charging with 2, 3 or 4 Depot Charge Boxes GEN2
The main principle of the sequential charging is to complete the bulk charge for all the buses that are
connected to the charger, before they leave the depot in the morning. The sequence will be based on
the principle first come, first serve.
Start charging:
1. Park the electric vehicle with the charge inlet within reach of the connector.
2. Turn off the electric vehicle.
3. Connect the charger’s connector to the vehicle’s charge inlet.
4. When there is no other bus already connected that requires bulk charging:
•The charger will automatically start to charge the vehicle after the preparation phase,
and will indicate the progress by the LED state (see figure 3).
5. When there is another bus already connected that is being charged:
•The LED state will turn to green and start blinking until the other charge sessions are
complete. After completing the other charge session(s) the charger will automatically
start to charge the vehicle after the preparation phase, and will indicate the progress
by the LED state (see figure 3).
Stop charging:
6. The charge session will automatically stop after completing the bulk charge mode (standard
setting is 95% SOC for this setup but this can be customized).
7. If there is another bus connected to the charger that requires bulk charging the charger will
stop the session and automatically switch to the next bus in line.
8. The charge session can also be stopped manually by either pushing the stop button on the
Depot Charge Box GEN2 or the stop button on the bus (not available on every bus).
9. If the stop button is pressed and there is another vehicle connected that requires bulk charg-
ing, the charging will automatically switch to the next bus in line.
10. When the charging is stopped automatically or by pressing the stop button, the connector is
unlocked by the vehicle for CCS.
11. Take the connector out of the vehicle and put it back in the connector holder on the Depot
Charge Box GEN2.
NOTICE
Session end
Charging will stop without user interaction:
•When the EV indicates to the charger that charging is
completed.
•When the charger completed the bulk charge.
If the battery is not full, a new charge session can be started.

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NOTICE
Stop by emergency button
The charger stops the charge session when the emergency stop
is pushed. Only push the emergency stop if there is an emer-
gency!
3.3 Emergency stop
If there is an emergency:
1. Push the emergency stop button (B in figure 2).
The Charger stops the operation and the LED beacon from each connected Depot Charge Box GEN2
will be red.
2. Contact the Site operator.
NOTICE
Emergency button is pressed accidentally
If the emergency stop button is accidentally pushed:
1. Verify that the situation is safe.
2. Pull the emergency out.
•The emergency button is released and the charger is re-
activated.
•After a few seconds the charger returns to normal opera-
tion.

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4 Operator Instructions
4.1 Cleaning of the cabinet and Depot Charge Box GEN2
DANGER
Electrical components
•Do not apply high-pressure water jets. Water may leak into the cabinet.
•Only use cleaning agents with a pH value between 6 and 8.
•Do not use cleaning agents with abrasive components.
•Do not use abrasive tools.
The cabinet of the Power Cabinet and Depot Charge Box GEN2 is made from powder coated high
quality stainless steel. The coating must be kept in good condition.
Clean the Charger three times a year in the following way:
•Remove rough dirt by rinsing with low-pressure tap water.
•Apply a neutral or weak alkaline cleaning solution and let it soak.
•Remove dirt by hand with a non-woven nylon hand pad.
•Rinse thoroughly with tap water.
•Optionally, apply wax on the front for extra protection and gloss.
•Check the coating on damage.
NOTICE
Rust forming
When the charger is placed in a corrosion sensitive environment, the forming of super-
ficial rust is possible on the welding points on the side grills. This rust is merely visual,
there is no possibility this will form a risk on the cabinets integrity.
The
rust can be removed with the cleaning procedure above. To prevent the rust from
reappearing;
prime the areas with a transparent or color-like priming finish.
4.2 Preventive maintenance
Maintenance is done according to the maintenance schedule. The charger must be inspected and ser-
viced yearly by a certified technician.
4.2.1 Service inspection of the cabinets
The following points must be checked regularly:
•Internal RCDs and RCBOs need to be tested on correct functioning on a regular basis. During
the yearly maintenance round that is advised to be executed by a certified ABB technician, this
will be checked.
•Powder coating: look for damage, cracks or ruptures.

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4.2.2 Emergency stop inspection
It is advised to test the emergency button every time someone of the operator or service organization
visits the location of the charger. This test needs to be done at least once a year e.g. during a preventive
maintenance round.
Test only when the charger is in idle mode and ready to charge:
1. Press the emergency button.
•The indicator light (beacon) will turn red.
2. Reset the emergency button by turning the knob clockwise.
•After a few moments, the charger returns to its idle state.
4.2.3 Special inspections
In the following cases the charger must be checked by ABB service personnel before further use:
•If it was struck by lightning.
•If it is damaged due to an accident or fire.
•If its location has been flooded.
4.3 Problem resolving
The site operator or helpdesk is the first response to a customer call. The helpdesk can remotely solve
simple problems for the customer.
In special cases the site operator with knowledge of the charger can be asked by ABB support to report
about the status of some internal components of the charger. Therefore a brief description of the position
and function of these components is described on the next pages.
4.3.1 Overview of the Power Cabinet
A Door
B Door handle / lock (per Power Cabinet
Unique system key)
WARNING
Do not open the Power Cabinet door if you are not familiar with working with high volt-
age and high
current.

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4.3.2 Overview of the Depot Charge Box GEN2
A Front door Depot Charge Box GEN2
B Door handle / lock (per Depot Charge Box GEN2
Unique system key)
WARNING
Do not open the
Depot Charge Box GEN2
door if you are not familiar with working with
high voltage and high current.
4.3.3 Component overview Power Cabinet
The main components as can be seen with an open front door:
A Main switch
B MCB (Q17) AC power supply for ACM
C RCD (Q13) control
D RCD (Q12) redundant control
E Display

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4.3.4 Component overview Depot Charge Box GEN2
The main components as can be seen with an open front door:
A SPD (F4) AC Power Supply
B MCB (F5) AC Power Supply
C Fuse (F1,F2) DC Circuit
D SPD (F3) DC Power Circuit
4.4 Technical functioning
4.4.1 Normal operation
Normal positions of the different switches and breakers when the charger is in operation (idle; not charg-
ing):
Power Cabinet
•Main switch (A): Vertical (“1”)
•MCB (Q17) AC power supply for ACM (B): up
•RCD (Q13) control (C): up
•RCD (Q12) redundant control (D): up
Depot Charge Box GEN2
•SPD (F2) AC Power Supply: green
•MCB (F1) AC Power Supply: up
•Fuse (F3,F4) DC Precharge Circuit: not blown
•SPD (F5) DC Power Circuit: green
4.4.2 Switch the charger system on/off
In case it is necessary to switch off the charger system, this can be done by turning off the main switch
(A in Power Cabinet, see section Component overview Power Cabinet on page 15):
1. Open the front door.

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2. Locate the main switch (A).
3. Turn the handle counterclockwise to the horizontal position, marked with “0”.
WARNING
Switching off the charger does not switch off
Depot Charge Box GEN2
. Each box has
its own power supply. To turn off the
Depot Charge Box GEN2 see chapter 0
To switch the charger back on, turn the handle clockwise to the vertical position, marked with “1”. After
about a minute the indicator light (beacon) will turn green.
NOTICE
Operating the main switch is quite arduous. Use both hands if needed and be careful
not to injure yourself.
4.4.3 Switch the Depot Charge Box GEN2
In case it is necessary to switch off the Depot Charge Box GEN2, this can be done by turning off the
main switch:
1. Open the front door.
2. Locate the main switch (B).
3. Move the MCB switch down (OFF position). Green painting on the switch should be visible
NOTICE
Every box has its own power supply line.
Following procedure should be performed for every box which should be powered off.

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5 Contact information
NOTICE
In
case of problems
Contact the site operator.
ABB in your country
Please contact ABB in your country for delivery and service information.
ABB EV Infrastructure global
ABB EV Infrastructure
AddressHeertjeslaan 6
2629 JG Delft
The Netherlands
Telephone [phone]
Mail [email protected]
Write down here your local ABB contact details:

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Appendix: A. WEEE disposal – 2012-19/EU

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NOTES