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
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 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.
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contents thereof must not be imparted to a third party nor used for any unauthorized purpose.
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All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
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