ABB Terra DC Wallbox C UL User manual

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MANUAL: NORTH AMERICA
Terra DC Wallbox UL
Three-phase Version Installation Manual
Rev 2.1

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 pres-
ence 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
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should consult the product specifications for the particular ABB product.
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tial damages arising from use of any software or hardware described in this document.
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Copyrights
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2021 ABB. All rights reserved.

Contents
1Introduction ...........................................................................................................................................6
1.1 Preface.................................................................................................................................................... 6
1.2 Intended document users .................................................................................................................. 6
1.3 Terra DC Wallbox hardware ordering details .................................................................................. 6
1.4 Signs ........................................................................................................................................................7
1.4.1 Owner responsibilities........................................................................................................ 8
1.4.2 Tilting and handling ............................................................................................................ 9
1.4.3 Sharp edges.......................................................................................................................... 9
1.4.4 Electric hazards.................................................................................................................... 9
1.4.5 Installation safety................................................................................................................ 9
1.5 Environment and disposal of waste................................................................................................10
2Description of the product.................................................................................................................10
2.1 Overview of the system .....................................................................................................................10
2.1.1 Complete overview.............................................................................................................10
2.1.2 External view ....................................................................................................................... 11
2.1.3 Inside view ...........................................................................................................................12
3Installation Planning and Design ....................................................................................................... 13
3.1 Internet connection ............................................................................................................................13
3.1.1 Internet via cellular connection........................................................................................13
3.1.2 Internet via ethernet connection.....................................................................................13
3.2 Electrical requirements......................................................................................................................13
3.2.1 Required electrical grid configuration ...........................................................................14
3.2.2 Overcurrent protection device .........................................................................................15
3.2.3 Conduit for power input wires.........................................................................................15
3.2.4 Specification for power input wires ...............................................................................15
3.2.5 Conduit for ethernet cable ...............................................................................................16
3.2.6 Specification for ethernet cable......................................................................................16
3.3 Terra DC Wallbox placement .............................................................................................................16
3.3.1 Charging cable reach .........................................................................................................16
3.3.2 Terra DC Wallbox position with respect to parking space ......................................... 17
3.3.3 Required space for installing and maintaining the Terra DC Wallbox ......................18
3.3.4 Ventilation and airflow required for the Terra DC Wallbox .........................................19
3.3.5 Considerations for where to position Terra DC Wallbox vertically............................19
4Installation instructions .....................................................................................................................20
4.1 About construction............................................................................................................................ 20
4.2 Instruction for a wall bearing........................................................................................................... 20
4.2.1 Mounting on a pedestal ................................................................................................... 20
4.3 Power feed........................................................................................................................................... 20
4.4 Internet connection ........................................................................................................................... 20
5Receiving, Placing and connecting .................................................................................................... 21
5.1 Receiving the Terra DC Wallbox........................................................................................................21
5.2 Unpacking the charging and mounting preparations .................................................................21
5.2.1 Unpacking ............................................................................................................................21
5.2.2 Mounting preparations .................................................................................................... 22
5.3 Move cabinet to position.................................................................................................................. 23

5.3.1 Options................................................................................................................................ 23
5.4 Mounting the Terra DC Wallbox....................................................................................................... 23
5.4.1 Mounting the Terra DC Wallbox ...................................................................................... 23
5.4.2 Install cable gland(s) or connect conduit to the unit.................................................. 28
5.5 Connect cables ................................................................................................................................... 29
5.5.1 Connect PE of power cable.............................................................................................. 29
5.5.2 Connect power cable ........................................................................................................ 30
6Commissioning .................................................................................................................................... 31
6.1 Commissioning preparation .............................................................................................................31
7Maintenance and Cleaning of the cabinet ........................................................................................ 32
7.1 Recommended Periodic maintenance ........................................................................................... 32
7.2 Cleaning of the cabinet..................................................................................................................... 32
8Technical Data...................................................................................................................................... 33
8.1 Electrical data ..................................................................................................................................... 33
8.2 Mechanical data ................................................................................................................................. 34
8.3 Environment........................................................................................................................................ 34
8.4 Certifications ...................................................................................................................................... 34
9Contact information ...........................................................................................................................35
10 Appendix A – Mounting points ...........................................................................................................36
10.1 Terra DC Wallbox Charger wall mounting...................................................................................... 36
11 Appendix B - Disposal instruction ..................................................................................................... 37
11.1 Directive on Waste Electrical and Electronic Equipment (WEEE – 2012/19/EU).....................37
12 Appendix C – Pedestal requirements ................................................................................................38

Glossary
AC
Alternating Current.
CCS
Combined Charging System. This is the name of
the charging protocol of European and North
American car makers.
CHAdeMO
DC fast charging method for electric vehicles.
Contractor
Entity hired by the owner / site operator to do
engineering, civil and electrical installation
work.
DC
Direct Current.
EV
Electric Vehicle.
Grid provider
Company responsible for the transportation
and distribution of electricity.
HMI
Human Machine Interface; the display/screen on
the charger.
NOC
ABB Network Operating Centre; remotely checks
the correct functioning of the charger.
Owner
The legal owner of the charger.
OCPP
Open Charge Point Protocol. Open standard for
communication with charge stations.
PE
Protective Earth.
PPE
Personal Protective Equipment.
Equipment such as safety shoes, helmet,
glasses, gloves.
RCD
Residual Current Device. Breaks the connection
if a residual current is detected.
RFID
Radio-Frequency IDentification. RFID is a com-
munication technology by means of radio waves
to transfer data over a very short distance be-
tween a reader and an electronic tag or card.
Site operator
This entity is responsible for the day to day con-
trol 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.

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1Introduction
1.1 Preface
This guide provides an overview for the installation of the Terra DC Wallbox.
The Terra DC Wallbox charging station is an easy to install DC fast charger for electric vehicles. Fast
chargers are electrical installations with high electric currents. Therefore, the installation must be
planned carefully, and must be done by certified personnel only (according to local standards). Local
regulations shall take precedence if they list different installation requirements than prescribed in this
Installation Manual.
The Terra DC Wallbox is offered in a variety of configurations and with multiple connector types. The
different versions are described in section 1.3.
Before installing the Terra DC Wallbox, read this installation guide carefully and attentively. Be sure to
follow all instructions when installing the charger. ABB is not responsible for any damage caused by not
following or incorrectly executing the instructions described in this manual.
1.2 Intended document users
This document is intended to be used by:
•Customers who have purchased a Terra DC Wallbox or customers in the process of ordering and
require additional details on installation.
•Contractors who are responsible for site preparation and/or installation of a Terra DC Wallbox.
1.3 Terra DC Wallbox hardware ordering details
ABB’s Terra DC Wallbox single-phase is offered in the following configurations:
-Terra DC Wallbox C UL
-Terra DC Wallbox CJ UL
C CCS-1 (Combo) standard
J CHAdeMO standard
CJ CCS-1 (Combo) standard and CHAdeMO standard
All variations are offered with charging cable lengths of 7 meters (23 ft). The Terra DC Wallbox comes
with the standard connector holsters as shown.

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Optional connector holsters shown below may be purchased separately with the order code details
shown below.
Charging cable type
ABB order code
CCS-1
ABB6AGC076604
CHAdeMO
ABB6AGC076601
1.4 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.

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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.
CAUTION
Various
Identifies a hazard that could result in damage to the machine,
other equipment, and/or environmental pollution.
CAUTION
Environmental damage
Identifies a hazard that could result in environmental damage
and/or environmental pollution.
NOTICE
Contains remarks, suggestions or advice.
1.4.1 Owner responsibilities
The owner and site operator are required to:
•Operate the charge station with the protective devices installed and to ensure all protective de-
vices are correctly installed after carrying out installation or maintenance work.
•Write an emergency plan that instructs people what to do in case of emergency.
•Prepare the site where the charge station will be installed according to the requirements de-
scribed in this guide.
•Ensure there is sufficient space around the charger to carry out maintenance work.
•Appoint a person responsible for the safe operation of the charge station and for the coordina-
tion of all work.
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 dam-
ages, 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 with ABB’s operating and maintenance instructions.

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1.4.2 Tilting and handling
WARNING
Heavy equipment
The Terra DC Wallbox weighs approximately 70 kg. Follow the han-
dling Instructions:
1. Two people are recommended for the installation and wall-
mounting of a Terra DC Wallbox.
2. Do not drop the Terra DC Wallbox.
1.4.3 Sharp edges
WARNING
Sharp metal edges
There could be sharp metal edges inside the Terra DC Wallbox. It is
recommended to wear mash protecting gloves when working in-
side the charger.
1.4.4 Electric hazards
DANGER
Hazardous voltage
The Terra DC Wallbox contains conductors under hazardous electri-
cal voltages. The grid terminals on the internal DIN rail may carry
hazardous voltages, even if all circuit breakers are switched off.
1.4.5 Installation safety
DANGER
Hazardous voltage
Instructions:
1. Always switch off the input circuit feeding the unit, (external dis-
connect or breaker) before performing any installation, disassem-
bly, repair or replacement of components. Follow appropriate re-
quirements for safe work practices, including but not limited to
NFPA-70e.
2. Perform a voltage check to ensure electrical power is discon-
nected from the system.
3. Only ABB certified technicians should commission the Terra DC
Wallbox.
4. When the system is in an open or dangerous condition, do not al-
low unqualified persons to go near it. Instruct and warn people
about the potentially harmful high voltages.
5. The installation and maintenance personnel must supply their
own lighting equipment because the Terra DC Wallbox has no lights
inside the cabinet.
6. Always connect the Protective Earth (PE) first, before connecting
the other power input wires.
7. Be sure to properly and securely reassemble the Terra DC Wall-
box’s enclosure after installation or service operations.
8. When handling the equipment, a proper lifting device should be
used in accordance with your local EHS policies.

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1.5 Environment and disposal of waste
NOTICE
Always follow the local rules and regulations regarding disposal of
any (non-reusable) Terra DC Wallbox parts.
2Description of the product
2.1 Overview of the system
2.1.1 Complete overview
Example of a complete installation
A Power distribution board of the owner
B Cables in conduit
C Terra DC Wallbox
D Parking space for charging
E Electric vehicle

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2.1.2 External view
A Display / HMI E Emergency stop button
B RFID card reader F AC input connection point for Conduit
C DC Charging cable G Air inlet
D Air outlet H Standard Holster (included)
I Optional Holster (purchased separately)
Standard charging
cable holster supplied
with Terra DC wallbox
Optional charging cable
holster sold separate from
Terra DC wallbox

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2.1.3 Inside view
A AC input board D Cable gland for DC output(2x)
B CPI and IMI boards E Cable gland for AC input
C External Fan (2x)

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3Installation Planning and Design
This section provides several considerations for the Terra DC Wallbox installation planning and design,
which are to be made by the customer to ensure a successful project.
3.1 Internet connection
ABB requires an internet connection to the Terra DC Wallbox to conduct remote service operations in-
cluding, oversight of the product during the warranty period, diagnosis and troubleshooting of issues,
and performing software firmware update. Not having internet connection to the Terra DC Wallbox may
severely impact, or even void, the product warranty and/or ABB’s service level agreement (SLA).
It is the installer’s responsibility to ensure reliable internet connection to the Terra DC Wallbox is made.
Contingency planning and the associated costs are the responsibility of the installer.
3.1.1 Internet via cellular connection
The preferred method of establishing internet connection to the charger is using the charger’s standard
featured hardware with ABB’s Charger Connect service offering, which provides internet access via Vo-
dafone’s 4G LTE wireless network.
In the USA, Vodafone primarily roams on the AT&T and T-Mobile 4G LTE networks. It is expected that a
cellular availability test is performed prior to construction to ensure there is reasonable signal quality to
at least one of the AT&T and T-Mobile 4G LTE bands 2 (1900 MHz), 4 (1700/2100MHz), or 12 (700 MHz).
The signal strength must be greater than -85dbm and should be measured with a cellular network signal
meter, such as a Squid-4G or Sure Call device. Handheld mobile phones are not recommended for as-
sessing signal strength since they are not reliable measuring devices.
The Terra DC Wallbox only supports SIM cards provided by ABB. Customer procured SIM cards are not
supported.
3.1.2 Internet via ethernet connection
Internet connection to the charger may be performed by connecting an ethernet cable to the charger
from other on-site IT infrastructure. However, due to the scope of work required for integrating this so-
lution to ensure secure communication, this method is typically not preferred.
ABB may require additional commissioning fees if ethernet cable method for establishing internet is
used, depending on the situation. Please contact your ABB sales representative for more details.
See sections 3.2.5 and 3.2.6 for more details on connection of conduit carrying ethernet cable and speci-
fication of the ethernet cable.
3.2 Electrical requirements
CAUTION
The installation company is responsible to design and install the
electrical installation according to the local regulations.

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3.2.1 Required electrical grid configuration
It is essential that the Terra DC Wallbox 3-phase input variant is installed in the proper electrical grid
configuration. The allowable grid configuration is shown in the figure below.
Electrical grid configuration required for 3-phase, Terra DC Wallbox UL variant (3ø, 480Y/277V input)
3-phase
480Y/277V
Terra DC
Wallbox
Neut ral
Grounding
Electrode
Conductor
277V
480V
Li n e 1
Li n e 2
Li n e 3
Neutral
Ground
Line 1
Line 2
Line 3
40A fused
switch or
circuit breaker

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NOTICE:
The grid connections shown for the various configurations of the Terra DC Wallbox are mandatory.
Failure to adhere to these instructions may partially or fully void the product warranty, result in a
costly site visit to reconfigure the grid configuration, and/or cause several site visits for the Terra
DC Wallbox commissioning. ABB is not responsible for scheduling delays and additional costs from
not properly planning the installation. If ABB is contracted to perform the Terra DC Wallbox com-
missioning, ABB observes the right to charge additional money for more than one site visit required
for the commissioning due to an initial, improper installation of the Terra DC Wallbox.
Important steps to ensure project success include:
1. Identify the grid configuration at the location where the Terra DC Wallbox will be installed. If
the grid configuration available is not okay for use with the Terra DC Wallbox, then determine
how to establish the required grid connection. A transformer solution offered by ABB is avail-
able to derive the required grid configuration when the required grid configuration is not
available. Contact your local ABB sales representative for more details.
2. Select the 1-phase or 3-phase variant of the Terra DC Wallbox according to Section 1.3 titled
Terra DC Wallbox hardware ordering details based on Step 1 above.
3. Carefully execute a project plan to ensure the correct variant of Terra DC Wallbox is used on
the project and that the project site’s grid configuration is compatible with the Terra DC Wall-
box.
4. Verify the actual grid configuration the Terra DC Wallbox is installed in matches the described
criteria during the Terra DC Wallbox commissioning.
3.2.2 Overcurrent protection device
Each variant of the Terra DC Wallbox is recommended to be fed by the circuit breaker or fuse ratings
shown below.
•3-phase, 480Y/277V Terra DC Wallbox variant: 3-pole, 40A circuit breaker or fuses
3.2.3 Conduit for power input wires
Each variant of the Terra DC Wallbox supports up to a 1-1/4” trade size conduit connection.
3.2.4 Specification for power input wires
The exact size and type of wires used must be defined by the customer and be protected by customer
provided overcurrent protection according to local codes and regulations.
The input terminals for 3-phase UL variants of the Terra DC Wallbox accept a range of wire sizes from 10
AWG to 0 AWG. Wire terminals are rated 75C.
The 3-phase UL variant Terra DC Wallbox requires Three (3) phase wires, One (1) neutral wire, and One (1)
wire for protective earth. (3W+N+G)
All wires for 3-phase variants of the Terra DC Wallbox may connect directly to the ABB provided termi-
nals, with exception to the protective earth wire. The protective earth wire requires for the installer to
crimp a terminal onto it using the terminal manufacturer’s recommended crimp procedure and tool.

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The integrity of the electrical grounding is essential. Ensure that the equipment grounding terminal is
used in the device and an actual grounding conductor is installed to provide a path back to the source
upstream panel. (Do not use the conduit or raceway as the sole equipment grounding conductor).
3.2.5 Conduit for ethernet cable
The Terra DC Wallbox does not have a hole designated for a conduit carrying only an ethernet cable to
connect to. If ethernet cable solution is required for an installation, please contact your ABB sales con-
tact person to review ethernet cable entry solutions.
3.2.6 Specification for ethernet cable
If the cellular connection is not available, ethernet connection must be made to the charger using a
shielded 8P+PE ethernet cable with RJ45 connectors. Additional recommendations include:
•Maintain distance of 75 meters or less. Distances over 75 meters require a custom engineered
solution.
•Minimum bandwidth:
upload: 128 kb/s
download: 4 Mb/s
•99.9% availability
•600V rated cable that may route beside input power wires for short distances
3.3 Terra DC Wallbox placement
Placement of the Terra DC Wallbox must be carefully determined by accounting for charging cable reach,
Terra DC Wallbox position with respect to parking space, bollards and wheel stops, ventilation and
working clearances, and other local codes and regulations (e.g. ADA requirements in the USA).
3.3.1 Charging cable reach
The Terra DC Wallbox charging cables are available in lengths of 3.5 or 7 meters. The charging cables exit
the charger enclosure on both the right and left sides. The cables and the connectors mounted on the
cables are different depending on the charging standard and vary in flexibility.
The figure below shows an example of a dual connector charger with both types of connector and the
corresponding reach area. The green circle with a continuous line describes the CHAdeMO cable 3.5m
and the red circle with a continuous line describes the CCS cable 3.5m. The broken lines indicate the
same cable types with a length of 7 meters (23 ft).

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3.3.2 Terra DC Wallbox position with respect to parking space
The charging inlets on a vehicle can be located at different positions depending on the manufacturer.
The most common vehicles have inlets located either on the front or in the back on either the left or
right side.
This makes some charger placements with respect to the parking space more favorable than others.
Keep this in mind when designing a site. Below are examples of possible situations:

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3.3.3 Required space for installing and maintaining the Terra DC
Wallbox
The Terra DC Wallbox requires a minimum space of 36” x 48”. This space is calculated as follows:
- Charger size (H x W x D): 30.3 x 23 x 11.8 in
- Bottom side 23.6” (15.75” from the Terra DC Wallbox in order to avoid obstacles for the electrical con-
nection).
- Left and right side 300mm/12”, in order to operate without obstacles on the lateral side of the Terra
DC Wallbox.
Note: The below dimensions are shown in millimeters.

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3.3.4 Ventilation and airflow required for the Terra DC Wallbox
The Terra DC Wallbox has an air inlet on the bottom side and an outlet on the top side.
NOTICE
Free air flow
If necessary, take precautions to prevent snow or objects from
blocking the inlets and outlets.
3.3.5 Considerations for where to position Terra DC Wallbox vertically
The below picture shows the height of the operable parts and display screen from the top and bottom
of the Terra DC Wallbox’ s enclosure (not accounting for piece on enclosure where the customer con-
duits connect to). It is the installer’s responsibility to use this information to define the height at which
to install the Terra DC Wallbox from the ground and to ensure compliance to local codes and regulations
(e.g. ADA requirements in the USA).

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4Installation instructions
4.1 About construction
The construction phase includes all work required to prepare the location and ensure it is ready for the
placement and connection of the Terra DC Wallbox charger. The construction phase can start when:
•The wall preparation work is done.
•All necessary permits are granted.
•The grid connection is available.
4.2 Instruction for a wall bearing
1. Drill and tap 4 holes and insert the plug for fixation in the wall at the indicated positions (refer
to technical drawing in the Appendix A par. 10.1). For safety purposes, the number of recom-
mended fixing screws is 4xST7.3x70. This is assuming the appropriate type of wall plugs are
used (depends on wall’s characteristics, structure and type). It is the installer’s responsibility to
choose an appropriate wall plug and to plan for a load of 820 N on each plug.
2. When selecting the area along the wall for installation, ensure the required free spaces for the
Terra DC Wallbox cables are available (refer to section 3.4).
4.2.1 Mounting on a pedestal
The Terra DC Wallbox can also be mounted on a pedestal. In order to achieve a safe installation, the
minimum set of requirements are included in Appendix C – Pedestal requirements). For the ABB pedes-
tal solution, contact your local ABB sales representative.
4.3 Power feed
The power cable enters the charger from below. Use conduit, foam, or proper cable lugs and glands to
prevent animals from entering the AC or Ethernet cable inlets. (Reference Section 3.2 for feeder specifi-
cations)
4.4 Internet connection
The preferred method of communication is the wireless 4G modem integrated into the charger. A cus-
tomer SIM card is not required. A subscription for the SIM card is provided by ABB for select countries.
If there is no wireless signal available, a standard wired internet connection is required. (Reference Sec-
tion 3.1, 3.2.5 and 3.2.6 for wiring and connection methods)
•The connection must be available for the ABB service engineer and the NOC (Network Opera-
tion Center).
•Please contact ABB (800.825.2556 option 2) for a specific configuration.
If a separate internet connection is not used, please ensure the cable entry hole is closed to retain the
IP54 grade of the cabinet and prevent insects and small animals from entering the cabinet.