ABB Terra DC wallbox Mounting instructions

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USER MANUAL
Terra DC wallbox
User and Operation Manual

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Notice
This document contains information about one or more ABB products and may include a descrip-
tion 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 representa-
tion that all of the ABB products referenced in this document support all of the features of the de-
scribed or referenced standard. In order to determine the specific features supported by a particu-
lar 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
consequential 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 ABB, and the contents thereof must not be imparted to a third party nor used for any unau-
thorized purpose.
Copyrights
All rights to copyrights, registered trademarks, and trademarks reside with their respective own-
ers.
Copyright © 2019 ABB.

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Contents
Glossary .......................................................................................................................................................4
1. Introduction ......................................................................................................................................5
Signs ......................................................................................................................................................................6
Safety regulations ..............................................................................................................................................6
2.1. Overview of the system ......................................................................................................................8
2.2. MID certified Charger identification................................................................................................ 9
2.3. Energy Meter Readout:........................................................................................................................ 9
2.4. Charger configurations....................................................................................................................... 9
2.5. Standard usage................................................................................................................................... 10
2.6. Authorization to charge.....................................................................................................................11
2.7. Output Power vs. Output Voltage curve ............................................................................................11
3. Quick instruction charging............................................................................................................ 12
4. Operator Instructions .................................................................................................................... 17
4.1. Cleaning of the Terra DC Wallbox................................................................................................... 17
4.2. Service inspection of the cabinets ................................................................................................. 18
4.2.1. Special inspections .................................................................................................................... 18
4.3. Problem resolving............................................................................................................................... 18
4.3.1. Overview of the WallBox ........................................................................................................... 19
4.4. Troubleshooting .................................................................................................................................20
4.5. Recommended Preventive maintenance ......................................................................................20
5. Contact information ......................................................................................................................20

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Glossary
AC
Alternating Current.
CCS
Combined Charging System. A universal AC and DC charging system
CHAdeMO
DC fast charging method for electric vehicles.
DC
Direct Current.
EV
Electric Vehicle.
HMI
Human Machine Interface; the screen on the charger.
Owner
The legal owner of the charger.
OCPP
Open Charge Point Protocol. Open standard for communication with charge stations.
PE
Ground.
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.
RFID
Radio-Frequency Identification. is a communication technology that utilizes the radio frequency elec-
tromagnetic waves to transfer data over a very short distance between the reader and an electronic tag
or card.
Site operator
Person or company that controls the charge station. The site operator could be the owner, but not nec-
essarily.
User
The driver of an EV who uses the charge station.

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1. Introduction
1.1. Preface
The Terra DC Wallbox Charge Stations are easy to install DC fast chargers for electric vehicles. Fast
chargers are electrical installations with high electric currents.
This manual describes the general usage and daily operation instructions of the Terra DC Wallbox charg-
ing station.
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,
performing daily inspection and maintenance activities and who are able to perform simple
trouble 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 picto-
grams 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 experi-
ence. Besides the screens needed for the charging process, the interface has help screens
available to provide additional information.
1.3. Intended use of the charger
The Terra DC Wallbox charger consists of the at least one power cabinet. The outlets of the cabinet
are solely used to charge electric vehicles that are compatible with the supported charging stand-
ards.
1.4. Owner responsibilities
The owner and site operator are required:
•To prepare the site where the charging station will be installed, according to the require-
ments described in this guide.
•To make sure that there is enough space around the charger to carry out maintenance
work.
•To make sure all protective devices are correctly installed after carrying out installation or
maintenance.
•To operate the charging station with the protective devices installed.
•To write an emergency plan that instructs people what to do in case of emergency.
•To appoint a person responsible for the safe operation of the charging station and for the
coordination of all work. This person should be properly instructed by ABB or an ABB
trained service 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 damages, losses, costs or ex-
penses 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.

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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
as also damage to the machine, other equipment, and/or
environmental pollution.
WARNING
Pinch Hazard
Identifies a hazard that could result in injuries, in which
some body parts are pinched or crushed.
NOTICE
Contains remarks, suggestions or advice.
Safety regulations
WARNING
If a charging outlet is damaged, take the following steps:
1. Do not use the damaged charging outlet.
2. Contact 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.

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CAUTION
Connector locked
Do not apply a force on the locked cable during the charging
process. This might damage the inlet and locking mecha-
nism in the car or damage the charger.
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 re-
spective holders.
Only insert a connector into a suitable car inlet. Never use
excessive force.
CAUTION
No User serviceable parts inside
Do not allow any user to repair or manage the electronics
inside.

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2. Description of the product
2.1. Overview of the system
The user operated components are indicated on Figure 1.
A. Display / HMI.
B. RFID card reader.
C. Charging outlets DC.
D. Air outlet
E. Emergency button
F. AC input cable
G. Air inlet
Figure 1: Terra DC Wallbox Charger view
The charger can be equipped with two DC charging
cables with CCS or CHAdeMO connector or only with the CCS one.

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2.2. MID certified Charger identification
The nameplate contains all information relating to the Deutsche Messe EV regulation for the
measuring device calibration law. This is a field-installable upgrade. To recognize if a charger is
compliance to MID Directive, Check the charger label. The product compliance is indicated by the
info showed in the Highlighted box
The Label reports all the necessary info to be compliance to 2014/32/EU MID directive.
2.3. Energy Meter Readout:
A. Time (hh:mm:ss)
B. Date (YY-MM-DD)
C. Delivered DC power (kWh)
•Charger registration to the Federal authority:
ohttps://www.bundesnetzagentur.de/DE/Sachgebiete/ElektrizitaetundGas/Unternehm
en_Institutionen/HandelundVertrieb/Ladesaeulen/Anzeige_Ladepunkte_node.html
•Section 31-33 MessEG :
oMessEG is published on: https://www.gesetze-im-internet.de/messeg/index.html
(directly to standard link)
2.4. Charger configurations
Terra DC Wallbox Charger supports the following DC charging standards:
Indicator
Description
CJ
One CCS and one CHAdeMO outlets up to 60 A / 22.5 kW;
No simultaneous charging possible
C
One CCS outlet with output current/power; 60 A / 22,5 kW
J
One CHAdeMO outlet with output current/power; 60 A / 22,5 kW

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2.5. Standard usage
Usually, the Terra DC Wallbox Charger gets the power from the grid.
Figure 2: Terra DC Wallbox charger
Figure 3: Terra DC Wallbox charger with two outlets.

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2.6. Authorization to charge
Operation of the charger is possible with or without authorization. The authorization to charge can
be based on RFID or credit card payment methods. Operating a charger with authorization re-
quires a subscription to a back office. Authorization can either be an ABB supplied standard solu-
tion, or from an external company offering authorization solutions via OCPP.
2.7. Output Power vs. Output Voltage curve
The curve below shows the output power vs. the voltage output of the charger, reflecting that the
charger can operate at the 22.5kW power range for both 400VDC and 800VDC architecture battery
packs.
The DC Wallbox can output 22.5kW continuous power, with 24kW peak output capability.
Note that the continuous output power is limited when ambient temperature is higher than the
operating temperature range of -35 °C to +45 °C: ABB’s overheating protection algorithm will de-
rate the unit linearly up to +55 °C (this refers to location when charger is not exposed to direct so-
lar radiation).
In the Vout ranges 480 / 675 Vdc and 150 / 350 Vdc there is an automatic current limitation.
The above curve refers to the 240V L-L AC supplied 1-ph version and 3-ph versions of DCWB.
For the 1-ph 208V L-N AC supplied one has to be considered the input max current limitation to
100A that limits the max output power to 19,2kW@208 Vac [ref. to exact value mentioned in
datasheet].

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3. Quick instruction charging
To charge an electric vehicle (EV):
1. Park the EV with the charging inlet within reach of the connector, and turn it off.
2. Connect the charger’s connector to the vehicle’s charging inlet.

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3. Wait until the display shows you that the connection is OK.
4. Authorize the charging session by PIN code or RFiD card.

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5. Wait until the preparation for charging has been completed.
6. Wait until the charging process is done or press the stop button in order to stop the charging
session.

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7. When the charge session finished, press OK on the display
8. Disconnect the plug from the vehicle and place it on the plug holder.
Stop charging:
1. Select stop on the touch-screen.
2. Potentially you have to authorize again to stop, using the same authentication method as
was used to start. Note that for:
•The CCS standard, the car will unlock the outlet,
•The CHAdeMO, the charger will release the lock that is integrated in the CHAdeMO
outlet.
3. Take the connector out of the car and put it back in the connector holder on the charger.

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NOTICE
Locked connector
For CCS charging the EV locks the connector. If the user wants
to take the connector out of the car, it may be necessary to
unlock all doors of the EV, or use the ‘unlock charge connector
button’ on the car key, if present.
NOTICE
Session end
Charging will stop without user interaction:
•When the EV indicates to the charger that charging is
completed.
•When the maximum charge time set by the opera-
tor/owner has been reached.
If the battery is not full, a new charge session can be started.
In general, topping up the battery is slow-charging.

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4. Operator Instructions
4.1. Cleaning of the Terra DC Wallbox
Clean the DC Wallbox Cabinet once a year (during yearly maintenance) in the following way:
•Remove rough dirt by spraying with low-pressure tap water.
•Remove dirt by hand with a cloth rag.
•Rinse thoroughly with tap water.
•Optionally, apply wax on the front for extra protection and gloss.
•Do a check on the overall enclosure and on the frontal cover for cracks or other damages.
NOTICE
Ordinary cleaning
Keep the air inlets clean and free from snow and leaves or from
any other materials.
NOTICE
Rust forming
When the charger is placed in a corrosion sensitive environment,
the forming of superficial rust is possible on the welding points.
This rust is merely visual, there is no risk for the cabinet’s integ-
rity. The rust can be removed with the cleaning procedure de-
scribed above. To prevent the rust from reappearing; prime the
areas with a transparent or color-like priming finish (separate
Service Instructions are available).
NOTICE
When the Terra DC Wallbox Charger is exposed to rain, it is
sufficient to clean it twice a year.
CAUTION
Do not apply high-pressure water jets. Water may leak into
the cabinet. If a high-pressure water jet has been used,
make sure that the inside of the cabinet is dry.
- 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.

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4.2. Service inspection of the cabinets
The following points must be checked regularly (advised yearly):
•Internal RCM need to be tested on correct functioning on a regular basis by pressing the
“TEST button” on the device itself. During the yearly maintenance visit, a check is advised,
to be executed by a certified ABB technician.
•Cable and connector
Check for cracks or ruptures on the connector or cable, check whether no internal
wires of the cable are visible.
•Display screen
Check for damage and cracks.
•Powder coating
Look for damage, cracks or ruptures.
•Emergency stop button
Look for functionality and damage.
4.2.1. 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.
Do not power on until the charger has been inspected and approved.
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 Service 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.

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4.3.1. Overview of the WallBox
A. Front cover
B. Tipper bottom cover. The bottom cover can be opened
by removing the two screws (N).
C. AC screw terminal blocks
D. PE connection bar
E. Emergency button
F. Front air filter
G. Cellular antenna
H. RFID reader
I. HMI touch-screen display
L. Top air filter
M. Top cover
WARNING
Do not open the cabinet if you are not certified to work with electrical installa-
tions.
LOTO Steps (Lock Out Tag Out) commonly used by service consisting on cutting
energy feed on upstream breaker, RCD and disconnect, need to be followed by
any operator acting on the charger.

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4.4. Troubleshooting
What to do in case of:
•Vehicle crash
•Fire
•Fluid spill
NOTE: this section will be defined at a next review of this document.
4.5. Recommended Preventive maintenance
The charger must be inspected and serviced yearly by an ABB trained/certified technician.
NOTES
Air Filter: The air filters must be inspected every 12 months and replaced if required.
Environment characteristic and number of charging sessions may increase or decrease the number
of replacements during the lifetime of the charger.
A. De-energize unit, make sure that unit is de-energized with appropriated instruments (mul-
timeter), open cover, inspect air filter, clean or replace as needed.
To order replacement air filter, use the following global ID:
- front filter 6AGC074817
- top side filter 6AGC074819.
B. Check input connections and terminations for proper toque values
C. Check Grounding resistance
D. Exercise input breaker and output DC breakers
E. Open HMI cover, inspect capacitors and fuse connections.
F. Clean interior with compressed air.
G. Blow out rear cooling fins and remove any debris
H. Reassemble unit, energize verify input voltage, perform a charging session.
I. Using the connected network verify charging session details.
5. Contact information
Please contact your local ABB Service organization or Service partner for first line problem analysis
and solving. In case they cannot solve the problem, they will contact the second line Service organi-
zation.