ABB Terra DC wallbox User manual

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MANUAL: NORTH AMERICA
Terra DC Wallbox
Installation Manual

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
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support all of the features of the described or referenced standard. In order to determine the specific features supported
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Copyright © 2018 ABB.
All rights reserved.

Contents
1Introduction ................................................................................................................................................. 6
1.1 Preface ..........................................................................................................................................................6
1.2 Intended document users.............................................................................................................................6
1.3 Terra DC Wallbox variations ..........................................................................................................................6
1.4 Signs..............................................................................................................................................................7
1.4.1 Owner responsibilities .................................................................................................................7
1.4.2 Tilting and handling .....................................................................................................................8
1.4.3 Sharp edges..................................................................................................................................8
1.4.4 Electric hazards ............................................................................................................................8
1.4.5 Installation safety.........................................................................................................................9
1.5 1.6 Environment and disposal of waste........................................................................................................9
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
3Site design ...................................................................................................................................................13
3.1 Evaluate cellular connection.......................................................................................................................13
3.2 Evaluate site infrastructure.........................................................................................................................13
3.3 Electrical requirements...............................................................................................................................13
3.3.1 Conductor and cable diameter ..................................................................................................14
3.3.2 Short circuit current rating.........................................................................................................15
3.4 Spacing Requirements ................................................................................................................................15
3.4.1 Required space for installing and maintaining the Terra DC Wallbox ........................................15
3.4.2 Ventilation and airflow of the Terra DC Wallbox........................................................................15
3.5 Cable reach .................................................................................................................................................16
3.6 Different alignment possibilities .................................................................................................................17
4Site construction..........................................................................................................................................18
4.1 About construction .....................................................................................................................................18
4.2 Power feed..................................................................................................................................................18
4.3 Instruction for a wall bearing......................................................................................................................19
4.3.1 Mounting on a pedestal.............................................................................................................19
4.4 Power cable ................................................................................................................................................19
4.5 Internet connection ....................................................................................................................................20
5Receiving, Placing and connecting................................................................................................................21
5.1 Receiving the 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.................................................................................................24
5.4.2 Install cable gland(s) or connect conduit to the unit. ................................................................28
5.5 Connect cables............................................................................................................................................30

5.5.1 Connect PE of power cable ........................................................................................................30
5.5.2 Connect power cable .................................................................................................................31
5.5.3 Connect network cable ..............................................................................................................32
6Commissioning ............................................................................................................................................33
6.1 Commissioning preparation........................................................................................................................33
7Maintenance and Cleaning of the cabinet ....................................................................................................35
7.1 Recommended Periodic maintenance........................................................................................................35
7.2 Cleaning of the cabinet...............................................................................................................................35
8Technical Data .............................................................................................................................................36
8.1 Electrical data .............................................................................................................................................36
8.2 Mechanical data..........................................................................................................................................37
8.3 Environment ...............................................................................................................................................37
8.4 Certifications...............................................................................................................................................37
9Contact information.....................................................................................................................................38
10 Appendix A – Mounting points.....................................................................................................................39
10.1 Terra DC Wallbox Charger wall mounting ...................................................................................................39
11 Appendix B - Disposal instruction.................................................................................................................40
11.1 Directive on Waste Electrical and Electronic Equipment (WEEE – 2012/19/EU) ........................................40
12 Appendix C – Pedestal requirements ............................................................................................................41

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
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
This entity is responsible for the day to day control of
the charger. The site operator can be the owner, but not
necessarily.
User
The owner of an electric vehicle, who uses the Charge
Station to charge that vehicle.

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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 variations
ABB’s Terra DC Wallbox is offered in the following configurations.
Version
1-Phase
3-Phase
Terra DC Wallbox C UL
X
X
Terra DC Wallbox J UL
X
Terra DC Wallbox CJ UL
X
X
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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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.
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 devices are
correctly installed after carrying out installation or maintenance work.
•Write an emergency plan that instructs people what to do in case of emergency.

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•Prepare the site where the charge station will be installed according to the requirements described 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 coordination 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 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 with ABB’s
operating and maintenance instructions.
1.4.2 Tilting and handling
WARNING
Heavy equipment
The Terra DC Wallbox weighs approximately 70 kg. Follow the handling
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 inside the
charger.
1.4.4 Electric hazards
DANGER
Hazardous voltage
The Terra DC Wallbox contains 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.

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1.4.5 Installation safety
DANGER
Hazardous voltage
Instructions:
1. Always switch off the input circuit feeding the unit, (external disconnect
or breaker) before performing any installation, disassembly, repair or
replacement of components. Follow appropriate
NFPA-70e
requirements
for safe work practices.
2. Perform a voltage check to ensure electrical power is disconnected
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 allow
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
neutral (N) and Phase (P) wiring. For the single-phase variation, there is no
neutral wiring required.
7. Be sure to properly and securely reassemble the Terra DC Wallbox’s
enclosure after installation or service operations.
1.5 1.6 Environment and disposal of waste
NOTICE
Always follow the local rules and regulations regarding disposal of any
(non-reusable) Terra DC Wallbox parts.

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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 cable conduit (if required)
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 or Cable
C DC Charging cable G Air inlet
D Air outlet H Standard Holster (included)
I Optional Holster (purchased separately)
FIG H. Standard
FIG. I Optional

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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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3Site design
When selecting the site, there must first be an evaluation to determine the basic requirements for installa-
tion are met. Once selected, a site for EV charging can be designed in many different setups. This section
provides information on the placement of a charger with respect to parking spaces and the vehicle inlets for
the charging cable.
3.1 Evaluate cellular connection
The Terra DC Wallbox includes a 4G modem equipped with a GSM SIM card. When selecting the site, it is ex-
pected that a cellular availability test is performed. Recommended signal strength is >-85dbm, (-30dBm to -
85dBM is the optimum signal strength), this should be measured with a cellular network signal meter,
handheld mobile phones are not always reliable measuring devices.
3.2 Evaluate site infrastructure
Upstream overcurrent protection device (i.e. fuses or circuit breaker), verify protective device coordination
to provide proper sequence of protective device actuation during an event or fault.
Recommend surge protection device on upstream distribution board
Disconnect switch if required by local laws
Wiring configuration- 3-phase 480Y/277V (Neutral is needed) vs Single-Phase 208Y/120V or 240V (see grid
connection diagrams in Section 3.3)
3.3 Electrical requirements
The electrical installation must be completed according to the local safety and electrical regulations and
laws.
In general, the installer should follow the below outline for the electrical installation of the devices upstream the
installation.
-Recommended Wiring for the 3-phase 480Y/277V unit #8 AWG THHN Copper (minimum, size per
NEC and voltage drop requirements) connect to a 40Amp 3-pole input breaker. (3W+N+G)
-Recommended Wiring for the Single-phase unit, (208Y/120V or 120/240V split-phase) , #2 AWG
THHN Copper (minimum, size per NEC, temperature rating and voltage drop requirements) connect
to a 125Amp 2-pole input breaker. Terminal can take a maximum 1/0 wire. (2W+G)
-Ensure that the equipment grounding terminal is used in the device and an actual grounding con-
ductor 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).
-Fuses or equivalent circuit breaker rated to respect the charger specifications must be used.
-See Diagrams below for typical input grid connection syles.

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-
-
-
CAUTION
Responsibility to comply with local regulations
The installation company is responsible to design and install the electrical
installation according to the local regulations.
3.3.1 Conductor and cable diameter
The diameter of the ground cables’ electrical conductor depends on the length, method of installation, etc.
This must be determined by your contractor.
The maximum cross section is 35 mm2.
480Y/277V
3-phase unit
208Y/120V
1-phase unit
120/240V
1-phase unit

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The maximum diameter of the (grid) cable entering the cabinet is 32 mm. The minimum diameter of the
standard fitted cable gland insert is 22 mm. (The range of wire sizes accepted in the input terminal block are
#8 -1/0 AWG.)
The minimum and maximum size conduit recommended are 0.75” to 1.25” for the 3-phase unit and 1” to
1.5” for the Single-Phase unit, (existing holes are pre-punched for a 1.25” Trade size conduit fitting).
3.3.2 Short circuit current rating
The Short Circuit Current Rating (SCCR) of the upstream breaker should be coordinated with the short circuit
current of the feeding point where installation is done.
This is usually known and calculated by knowing the Short circuit current of the upstream transformer feed-
ing the electrical circuit where the installation is placed.
The Rating of the ABB Wallbox is ~4kAIC
3.4 Spacing Requirements
3.4.1 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 connec-
tion).
- Left and right side 12”, in order to operate without obstacles on the lateral side of the Terra DC Wallbox.
3.4.2 Ventilation and airflow of the Terra DC Wallbox
The Terra DC Wallbox has an air inlet on the bottom side and an outlet on the top side.

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NOTICE
Free air flow
If necessary, take precautions to prevent snow or objects from blocking
the inlets and outlets.
3.5 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 corre-
sponding 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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3.6 Different alignment possibilities
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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4Site construction
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 Power feed
The power cable enters the charger from below. Use conduit, foam, or proper cable lugs and glands to pre-
vent animals from entering the AC or Ethernet cable inlets.

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4.3 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 recommended
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 appro-
priate 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).
4.3.1 Mounting on a pedestal
The Terra DC Wallbox can also be mounted on a pedestal. In order to achieve a safe installation, the mini-
mum set of requirements are included in Appendix C – Pedestal requirements). For the ABB pedestal solu-
tion, contact your local ABB sales representative.
4.4 Power cable
•Cable type: two options
o3P+N+PE, shielded cables are optional but may be required by local law (3-phase).
o2P+PE, shielded cables are optional but may be required by local law (1-phase).
•Optional cable shielding must be attached to the PE Rail at both ends of the cable.
•The diameter of the cable conductor must be determined by your contractor / electrician.
•The maximum cross-sectional area of the cable conductor is 35 mm².
•The power cable’s PE conductor must have the same diameter as the phase conductors.

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4.5 Internet connection
The preferred method of communication is the wireless 4G modem integrated into the charger. A customer
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. This connection
must meet the following requirements:
•Ethernet, RJ45.
Cable type: 8P+PE, shielded.
•Recommendations:
For distances of 75 meters or less; HELUKAT 600E.
Distances over 75 meters require a custom engineered solution.
•Recommended minimum bandwidth:
upload: 128 kb/s
download: 4 Mb/s.
•Recommended availability: 99.9%.
•The connection must be available for the ABB service engineer and the NOC (Network Operation
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.
600V Ethernet cable tbc