ABB HVC User manual

—
INSTAL LATION GU IDE
HVC 450 kW E-Bus Charger
Installation Guide for NA products
Version 1.2
Attachment A

HVC 450 kW E-Bus Charger Installation Guide
Revision: 1.2 COMPANY CONFIDENTIAL
Date released: 16-08-2018 Page 2of 128
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 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
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 orconsequential 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 document.
This document is originally written in English. Other language versions are a translation of the
original document and ABB cannot be held liable for errors in the translation.
This document and parts thereof must not be reproduced or copied without written permission
from ABB, and the contents there of must not be imparted to a third party nor used for any
unauthorized purpose.
Copyrights
All rights to copyrights, registered trademarks, and trademarks reside with their respective
owners.
Copyright © 2018 ABB.
All rights reserved.

HVC 450 kW E-Bus Charger Installation Guide
Revision: 1.2 COMPANY CONFIDENTIAL
Date released: 16-08-2018 Page 3of 128
Version control
Documents data
Title
HVC 450 kW E-Bus Charger Installation Guide
Author
Richard de Gruyl
Version
1.2
Version Date
16-08-2018
Status
Final
Version
Date
Remarks
0.1
05-12-2017
Temporary version for customer. Document is still under construction.
0.2
24-01-2018
Release for review.
0.3
26-04-2018
Update numbering of the glass fiber cable and X4 connector block in
ACM. Conversion from m/mm to ft/Inch, Nm to ft-lb and kg to lb. Changed
PE to GND, and RCD to GFCI. Name Bus-bar Box changed in Junction
Box. Update cable list. Description added for own making pole foundation.
Numbering change of connector X4 in the ACM. Handling instructions for
connecting the glass fiber cable in ACM adapted.
1.0
30-04-2018
First commercial release.
1.1
20-07-2018
Height specification HVC 150 adapted. Adapt instruction for GND
connection in Power Cabinet. Removed UL Listing logo on page 112 and
put 2202 after UL in the table in 8.4.
1.2
16-08-2018
Correct description Interlock connection within salve 1 HVC150S (Mantis
PR10833). Remove sub-paragraph “Cables” and add cable specification
list. Update contact information.

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Revision: 1.2 COMPANY CONFIDENTIAL
Date released: 16-08-2018 Page 4of 128
Table of Contents
1. Introduction 8
1.1. Preface 8
1.2. Intended document users 8
1.3. Signs 8
1.4. Safety regulations 9
1.4.1. Owner responsibilities 9
1.4.2. Tilting and handling 10
1.4.3. Electric hazards 11
1.4.4. Installation safety 11
1.5. Environment and disposal of waste 12
1.6. Contact information 13
2. Description of the product 14
2.1. Overview of the system 14
2.1.1. Standard HVC 450 kW E-Bus Charger with pole 14
2.1.2. Standard HVC 450 kW E-Bus Charger without pole 15
2.1.3. Power Cabinet 16
2.1.4. ACS Control Module 17
2.1.5. Junction Box 18
2.1.6. ABB Pole 18
2.2. Accessories 19
2.2.1. Foundation for Power Cabinet 19
2.2.2. Foundation for ABB Pole construction 20
2.2.3. Communication glass fiber cable 21
2.2.4. Electrical components 21
2.3. Project planning 23
3. Preparation 24
3.1. About preparation 24
3.2. Permits 25
3.2.1. Power connection 25
3.2.2. Construction permit 25
3.2.3. Internet access 25
3.3. Upgrade grid 26
3.4. Location 26
3.5. Geometry of infrastructure 27
3.5.1. Required space for the Power Cabinet 27
3.5.2. Placement of multiple cabinets 28
3.5.3. Required space for the ABB pole 29
3.6. Pole position in relation to the bus 29
3.6.1. Pole position in relation to the drive direction of the bus 29
3.6.2. Pole position in sideways direction of the bus 30
3.6.3. Maximum slope of the road in sideways direction 32
3.6.4. Maximum slope of the road in driving direction 32
3.7. Electrical engineering 33
3.7.1. Electrical installation 33
3.8. Civil installation 33
3.9. Lightning protection 34
4. Construction 35
4.1. About construction 35
4.2. Construct foundation of the Power Cabinet 36

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4.2.1. Options 36
4.2.2. Workflow with pre-fabricated concrete foundation 37
4.2.3. Workflow with metal frame foundation 39
4.2.4. Workflow with custom foundation (footprint) 40
4.3. Construct foundation of the ABB Pole 41
4.3.1. Options 41
4.3.2. Pole foundation constructed on site or mounted on concrete floor 41
4.3.3. Workflow with pre-fabricated concrete foundation 42
4.4. Cabling 46
4.4.1. About cabling 46
4.4.2. Charge system configuration 47
4.4.3. AC power cable 47
4.4.4. Cables between the Power Cabinets and the ACS Control Module 47
4.4.5. Cables between the Power Cabinets 48
4.4.6. Cable specification list 48
4.5. Internet connection 50
5. Placement and Connection 51
5.1. About placement and connection 51
5.2. Route the cables 52
5.3. Unpack Power Cabinet 53
5.3.1. Before unpacking 53
5.3.2. Remove packaging 54
5.4. Move Power Cabinet to position 54
5.4.1. Move cabinet with a hoist 55
5.4.2. Move cabinet with a forklift truck 56
5.5. Install Power Cabinet onto the foundation 57
5.5.1. Connect Power Cabinet to foundation 57
5.5.2. Open the door of the Power Cabinet 59
5.5.3. Move the sliding plate of the guidance plates of the cabinet 60
5.5.4. Route cables through guidance plates 60
5.5.5. Move sliding plates of the guidance plates of the cabinet 61
5.5.6. Install border covers of the Power Cabinet 62
5.5.7. Install border covers of metal frame foundation 62
5.5.8. Install front cover plate on foundation 63
5.6. Connect AC power cable and GND wires Power Cabinets 64
5.6.1. Remove the protection covers 64
5.6.2. Connect the GND wire of the AC power cable 65
5.6.3. Connect the AC power cable 66
5.6.4. Install the protection covers 67
5.6.5. Install lightning protection (optional) 68
5.6.6. Connect the GND wire to the ABB Pole 69
5.6.7. Connect the GND wire between the Power Cabinets 69
5.7. Connect the DC power cables Power Cabinets 70
5.7.1. Remove the protection covers 71
5.7.2. Connect the DC power cables 71
5.7.3. Install the protection covers 72
5.8. Connect AC utility power, Interlock and CAN cables Power Cabinet 72
5.8.1. Route the cables to the terminal blocks 73
5.8.2. Connect the AC utility power cable 73
5.8.3. Connect the Interlock cable 74
5.8.4. Connect the CAN cable 77
5.9. Connect the communication cable Power Cabinet 80
5.9.1. Route the cable to the terminal blocks 80
5.9.2. Connect the communication fiber cables 80

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5.10.Close the door of the Power Cabinet 81
5.11.Unpack the Charge control set 82
5.11.1. Before unpacking 82
5.11.2. Remove packaging 83
5.12.Move the ABB pole to position 83
5.13.Install vertical frame onto the foundation 84
5.14.Install horizontal frame onto the vertical frame 86
5.15.Connect GND wires to ABB Pole 89
5.15.1. Connect the GND wire of the ACS GND 89
5.15.2. Connect the GND wire from the horizontal frame 89
5.15.3. Connect the GND wire from the Junction Box 90
5.15.4. Connect the GND wire of the Power Cabinet 90
5.15.5. Install lighting protection 91
5.16.Connect cables ACS Control Module 91
5.16.1. Gland layout of the ACS Control Module 92
5.16.2. Open the door of the ACS Control Module 92
5.16.3. Connect the DC+ power in- and output cables 93
5.16.4. Connect the DC- power in- and output cables in Junction Box 95
5.16.5. Connect the AC utility power cable from Power Cabinet 97
5.16.6. Connect the communication cable from the Power Cabinet 97
5.16.7. Connect the WiFi cable 99
5.16.8. Connect the RFID cables 99
5.16.9. Connect the other cables to the ACS Control Module 101
5.17.Close the door of the ACS Control Module 102
5.18.Install masks plate work 103
5.19.Grouting of the pole construction 108
6. Commissioning 109
6.1. Commissioning preparation 109
6.2. Customer Acceptance Form (CAF) 110
7. Service and Maintenance 111
7.1. About Service and Maintenance 111
7.2. Cleaning of the cabinet 111
8. Technical Specification 112
8.1. Electrical specification complete system 112
8.2. Mechanical data 112
8.3. Environment 113
8.4. Certifications 113
9. Appendix 114
A Dimensions Power Cabinet 115
B Dimensions ACS Control Module 117
C Dimensions Junction Box 118
D Dimensions ABB Pole 119
E Dimensions Concrete Foundation Power Cabinet 121
F Dimensions Metal Foundation Power Cabinet 123
G Dimensions pre-fabricated Concrete Foundation Pole 124
H Power Cabinet –Outline with Foundation 125
I Signal connection diagram 126
J Ground overview of the system 127
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.
Charge control set
Set of sub-system of the charger systems
which includes the ACS, thecontrol module
for the ACS, the communication unit and a
status indicator of the charge process.
DC
Direct Current.
GFCI
Ground Fault Circuit Interrupter
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.
PE
Protective Earth.
PPE
Personal Protective Equipment. Equipment
such as safety shoes, helmet, glasses,
gloves.
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.

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1. Introduction
1.1. Preface
This guide describes the planning and physical installation of the HVC E-Bus Charger at its
location for the North American (NA) region.
The HVC 450 kW 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 450
kW E-Bus Charger to charge any other equipment, or to use the HVC 450 kW E-Bus Charger
for any other purposes.
The HVC 450 kW 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).
Before installing the HVC 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 450 kW E-Bus Charger, or are in the process of
ordering and want to know in more detail how it has to be installed.
Contractors who areresponsible for site preparation and/or installation of the HVC 450
kW 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.

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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.

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You are not allowed to modify the charge system without the permission of ABB. The
owner is cautioned that changes ormodifications 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 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.
1.4.2. Tilting and handling
CAUTION
Heavy equipment
Handling instructions:
1. Use crane or forklift truck when lifting or moving the Power Cabinet
and pole construction.
2. Do not drop parts of the HVC 450 kW E-Bus Charger.
3. Do not exceed a tilting of 30⁰for 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
do the lifting and tilting work.
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,
because the activity:
Carry out within the framework of an effective management system;
Properly planned;
Risk has been assessed;
Supervision is being held; and
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 450 kW 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 for damage. See section Before unpacking
on Page 53 and section Before unpacking on Page 82. 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
450 kW E-Bus Charger.
4. When the system is in an open or dangerous condition, do not allow
unqualified persons to go near it. Instruct and warn people about the
potential harmful high voltages.
5. The installation and maintenance personnel must supply their own
lighting equipment, since the HVC 450 kW E-Bus Charger has no
lights inside the cabinet.
6. Always connect the Protective Earth (GND or PE) first, before
connecting the neutral (N) and Phase (P) wiring.
7. Correctly lock the door after installation or service operations.
WARNING
Make sure that there is a minimum free space of 39.37 Inch 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 if there
is an emergency when the door is open.

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WARNING
Make sure that there is a minimum free space of 39.37 Inch in front of
the door of the ACS Control Module. The minimum space is necessary
to allow service personnel to quickly move away from the ACS Control
Module if there is an emergency when the door is open.
CAUTION
Warranty
Installation and commissioning work must be carried out by certified
personnel. The warranty will be void if any work carried out by non-
certified personnel.
1.5. Environment and disposal of waste
CAUTION
Always observe the localrules and regulations with respect to processing
(non-reusable) parts of the HVC 450 kW E-Bus Charger.

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1.6. Contact information
ABB in your country
Please contact ABB in your country for sales, delivery and service information.
ABB EV Infrastructure global
ABB EV Infrastructure
Address Delftweg 65
2289 BA Rijswijk
The Netherlands
Telephone [phone]
Mail [e-mail]
Write down here your local ABB contact details:

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2. Description of the product
2.1. Overview of the system
Example of a complete installation
A Low voltage power distribution cabinet of the owner
B Input power cables in cable conduit
C Power Cabinet –450 kW (HVC 150 + 2x HVC 150S)
D Cables between Power Cabinet and charge pole in cable conduits
E Charge Pole with ACM and ACS
F Bus stop space for Opportunity Charging (OPP Charge)
G Electric hybrid and/or full electric Bus
The HVC 450 kW E-Bus Charger consists out of multiple components and it may require
additional parts depending on the project and location of installation which dictates whether
these parts are needed.
ABB offers two standard delivery system configurations:
1. Standard HVC 450 kW E-Bus Charger with pole.
2. Standard HVC 450 kW E-Bus Charger without pole.
Additional needed components can be ordered separately and are not part of the standard
delivery. See section Accessories on Page 19.
2.1.1. Standard HVC 450 kW E-Bus Charger with pole
The following parts are provided for this system configuration:
1x HVC 150 Power Cabinet
2x HVC 150S Power Cabinet
1x Pole construction including:
1x Vertical frame, with mounted:
1x ACS Control Module (ACM)
1x Junction Box
1x Distance sensor
1x Charge state indicator light
1x Emergency push button unit

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1x Horizontal frame, with mounted:
1x Pantograph (ACS)
1x WiFi communication unit (for the bus)
Premounted cable set for inside the pole
Masks Plate work and door
Pole mounting material
2.1.2. Standard HVC 450 kW E-Bus Charger without pole
The possibility to design your own pole locally or the site already has a construction like a roof
where the pantograph can be mounted on. In this case the system configuration provides the
following parts:
1x HVC 150 Power Cabinet
2x HVC 150S Power Cabinet
1x Charge control set, including:
1x ACS Control Module (ACM)
1x Junction Box
1x Pantograph (ACS)
1x WiFi communication unit (for the bus)
1x Charge state indicator light
NOTICE
The cables between the ACS Control Module and pantograph is not part
of the order. However, the length of the cable will depend on site survey
(for pole) conducted by ABB. ABB has a standard cable list (see section
Communication glass fiber cable on Page 21) to be used for these
cables, if the site has special conditions apart from being exposed to sun;
evaluation of the cables has to be done and this will be treated as a
separate work order.

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2.1.3. Power Cabinet
Outside view of the Power Cabinet
A Base cover D 3G Antenna
B Air outlet E Air inlets (also on the left and back side)
C Door F Door handle / lock
Inside view of the Power Cabinet
A Main switch D Data/communication connection
B AC Power connection E Display (only present in HVC 150)
C Guidance plate of the cables

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2.1.4. ACS Control Module
Outside view of the ACS Control Module
A Door
B Locks
C WiFi coax connector
D In- and outputs for cables from Power Cabinet and to pantograph
E In- and outputs DC power cables
Inside view of the ACS Control Module
A Communication connection
B Connection block
C Protection cover for DC contactors

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2.1.5. Junction Box
Outside view Junction Box
A Cover
B In- and outputs DC power cables
C Output DC- OVP sensing cable
2.1.6. ABB Pole
Outside view ABB Pole
A Door
B Emergency button (EMO)
C Charge state indicator light (beacon)
D Distance sensor
E Pantograph (installation specific)
F WiFi communication unit
G RFID unit (optional)

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View of the pantograph
A Base frame
B Lower arm
C Lower guide rod
D Upper arm
E Collector head guidance
F Tension spring
G Collector head
2.2. Accessories
The following parts can be ordered at the time of the initial order or afterwards. Contact ABB
Sales department (see Contact information on Page 13 for contact details).
2.2.1. Foundation for Power Cabinet
Pre-fabricated concrete foundation
The pre-fabricated concrete foundation can be used to install the Power Cabinet on soil.
A Foundation
B Top cover plate
C Front cover plate

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Metal frame foundation
The metal frame foundation can be used to install the Power Cabinet on a solid surface.
A Foundation
B Front border cover
C Rear border cover
2.2.2. Foundation for ABB Pole construction
Pre-fabricated concrete foundation
The pre-fabricated concrete foundation can be used to install the ABB Pole construction on
soil.
A Base plate
B Counter weights
Pulse tube foundation
The pulse tube foundation can be used to install the ABB Pole construction on soil.