ABB Terra HP Generation 3 User manual

Installation manual
Terra HP Generation 3 UL 175 kW Static
DC system
© Copyright ABB. All rights reserved

Copyright
All rights to copyrights, registered trademarks, and trademarks reside with their respective
owners.
Copyright ® ABB EV Infrastructure. All rights reserved.
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Contents
1 About this document.......................................................................... 8
1.1 Function of this document...................................................................................................... 8
1.2 Target group...............................................................................................................................8
1.3 Revision history..........................................................................................................................8
1.4 Language.....................................................................................................................................8
1.5 Illustrations.................................................................................................................................8
1.6 Units of measurement..............................................................................................................8
1.7 Typographical conventions..................................................................................................... 8
1.8 How to use this document...................................................................................................... 8
1.9 General symbols and signal words........................................................................................ 9
1.10 Special symbols for warnings and dangers....................................................................... 10
1.11 Related documents................................................................................................................. 10
1.12 Manufacturer and contact data............................................................................................ 11
1.13 Abbreviations............................................................................................................................11
1.14 Terminology.............................................................................................................................. 12
1.15 Orientation agreements.........................................................................................................13
2 Safety.................................................................................................. 14
2.1 Liability...................................................................................................................................... 14
2.2 General safety instructions................................................................................................... 14
2.3 Required qualifications for the installation person..........................................................14
2.4 Personal protective equipment............................................................................................ 15
2.5 Safety instructions during transport...................................................................................15
2.6 Safety instructions during installation................................................................................15
2.7 Safety instructions for earthing........................................................................................... 16
2.8 Signs on the EVSE....................................................................................................................16
2.9 Discard the EVSE or parts of the EVSE................................................................................ 17
2.10 Cyber security........................................................................................................................... 17
3 Description......................................................................................... 19
3.1 Intended use............................................................................................................................. 19
3.2 Type plate.................................................................................................................................. 19
3.3 General description of the EVSE.......................................................................................... 20
3.4 Working principle.................................................................................................................... 20
3.5 Overview and functions.......................................................................................................... 21
3.5.1 Power cabinet, outside...........................................................................................21
3.5.2 Power cabinet, inside............................................................................................. 22
3.5.3 DC output busbar in a static DC system............................................................ 23
3.5.4 Charge post CP500 Generation 3, outside........................................................ 23
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3.5.5 Charge post CP500 Generation 3, inside........................................................... 24
3.5.6 Overview of the cable glands of the charge post.............................................25
4 Pre-installation.................................................................................. 26
4.1 Pre-installation procedure (site planning)......................................................................... 26
4.2 Prepare the site........................................................................................................................26
4.3 Make sure that the floor space for the EVSE and the airflow around the EVSE is
correct........................................................................................................................................27
4.4 Prepare the foundation.......................................................................................................... 27
4.4.1 Prepare the foundation - general procedure..................................................... 27
4.4.2 Prepare a prefab concrete foundation for the power cabinet.......................27
4.4.3 Prepare a metal foundation for the power cabinet......................................... 28
4.4.4 Prepare a custom foundation for the power cabinet......................................29
4.4.5 Prepare a prefab concrete foundation for the charge post...........................30
4.4.6 Prepare a metal foundation.................................................................................. 31
4.4.7 Prepare a custom foundation for the charge post...........................................31
5 Inspection and transport..................................................................33
5.1 Transport the EVSE to the site............................................................................................. 33
5.2 Inspect the EVSE on delivery................................................................................................. 33
5.3 Do a check on the transport sensors...................................................................................33
5.4 Unpack the EVSE......................................................................................................................33
5.5 Remove the cabinet from the pallet.................................................................................... 34
5.6 Transport the EVSE on the site.............................................................................................34
5.6.1 General transport procedure................................................................................34
5.6.2 Tilt the charge post to the vertical position......................................................35
5.6.3 Move the cabinet with a forklift truck................................................................ 36
5.6.4 Hoist the cabinet.....................................................................................................36
6 Installation......................................................................................... 38
6.1 General installation procedure............................................................................................. 38
6.2 Mechanical installation of the power cabinet....................................................................38
6.2.1 Install the power cabinet - general procedure..................................................38
6.2.2 Install the cabinet on the foundation................................................................. 39
6.2.3 Open the cable inlets .............................................................................................39
6.2.4 Guide the cables to the cabinet...........................................................................40
6.2.5 Close the cable inlets ............................................................................................ 40
6.2.6 Install the front cover plate (concrete foundation).........................................40
6.2.7 Install the cover plates (metal foundation)....................................................... 41
6.3 Mechanical installation of the charge post........................................................................ 41
6.3.1 Install the charge post - general procedure.......................................................41
6.3.2 Remove the cable gland plates............................................................................ 42
6.3.3 Install the charge post on the foundation......................................................... 43
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6.3.4 Install the cable gland plates................................................................................43
7 Electrical installation of the power cabinet.................................. 44
7.1 General procedure...................................................................................................................44
7.2 Connect the PE cables to the power cabinet.....................................................................44
7.3 Connect the AC input cables.................................................................................................45
7.4 Connect the DC power cables...............................................................................................46
7.5 Connect the AC auxiliary power cable in the primary power cabinet........................... 47
7.6 Connect the interlock and DC guard cables to the power cabinet............................... 48
7.7 Connect the optical CAN cable between the power cabinet and the charge post....49
8 Electrical installation of the charge post.......................................50
8.1 General procedure...................................................................................................................50
8.2 Connect the PE wires..............................................................................................................50
8.3 Connect the DC power input cables.....................................................................................51
8.4 Connect the AC auxiliary power cable................................................................................. 52
8.5 Connect the interlock and DC guard cable.........................................................................53
8.6 Connect the optical CAN cable............................................................................................. 54
8.7 Connect the Ethernet cable...................................................................................................55
9 Prepare for commissioning..............................................................57
10 Access to parts.................................................................................. 58
10.1 Open the door of the power cabinet...................................................................................58
10.2 Remove the plinth covers of the power cabinet............................................................... 58
10.3 Remove the DC busbar cover................................................................................................59
10.4 Remove the AC covers............................................................................................................ 59
10.5 Close the door of the power cabinet.................................................................................. 60
10.6 Open the door of the charge post........................................................................................61
10.7 Remove the plinth covers of the charge post.................................................................... 61
10.8 Remove the protection plate of the charge post..............................................................62
10.9 Close the door of the charge post....................................................................................... 62
11 Generic procedures...........................................................................64
11.1 Install a cable lug on a wire................................................................................................... 64
11.2 Install a ferrule on a wire........................................................................................................64
11.3 Install insulating heatshrink tubing on a wire................................................................... 65
11.4 Connect a wire that has a cable lug.....................................................................................66
11.5 Connect a wire that has a ferrule......................................................................................... 66
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12 Technical data....................................................................................67
12.1 EVSE type.................................................................................................................................. 67
12.2 Parts included in the delivery................................................................................................ 67
12.3 Required tools for installation..............................................................................................68
12.4 Required parts for installation............................................................................................. 68
12.5 General specifications............................................................................................................69
12.6 Electrical installation specifications (North America)..................................................... 69
12.7 Electrical installation specifications (Canada)..................................................................70
12.8 DC output specifications.......................................................................................................70
12.9 Current peaks during the start of a charge session (DC output).................................. 71
12.10 Logic interfaces specifications.............................................................................................71
12.11 Mass and center of gravity.................................................................................................... 72
12.11.1 Mass........................................................................................................................... 72
12.11.2 Center of gravity, power cabinet......................................................................... 72
12.11.3 Center of gravity, charge post..............................................................................73
12.12 Ambient conditions.................................................................................................................73
12.13 Noise level................................................................................................................................. 74
12.14 Torque specifications.............................................................................................................74
12.15 Dimensions............................................................................................................................... 74
12.15.1 Power cabinet.......................................................................................................... 74
12.15.2 Charge post..............................................................................................................75
12.15.3 Height of user operable elements....................................................................... 76
12.16 Space requirements................................................................................................................ 77
12.16.1 Power cabinet.......................................................................................................... 77
12.16.2 Charge post..............................................................................................................78
12.16.3 Charge post: exceptions for bollards and other minor fixed obstacles......79
12.16.4 Distance requirements between power cabinet and charge post............... 80
12.17 Foundation specifications.................................................................................................... 80
12.17.1 Power cabinet (prefab concrete).........................................................................80
12.17.2 Power cabinet (metal frame)................................................................................84
12.17.3 Gland plates for the metal foundation of the power cabinet........................85
12.17.4 Power cabinet (custom)........................................................................................ 86
12.17.5 Charge post (prefab concrete).............................................................................87
12.17.6 Charge post (metal frame)................................................................................... 90
12.17.7 Gland plates for the metal foundation of the charge post.............................91
12.17.8 Charge post (custom)............................................................................................92
12.18 Overview of the cable conduits............................................................................................ 93
12.19 Cable specifications................................................................................................................95
12.19.1 AC input cable for the power cabinet................................................................. 95
12.19.2 DC power installation cables ...............................................................................95
12.19.3 PE cable.....................................................................................................................96
12.19.4 AC auxiliary power cables......................................................................................96
12.19.5 Interlock and DC guard cables..............................................................................97
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12.19.6 Optical CAN cables between the power cabinet and the charge post........ 97
12.19.7 Ethernet cable..........................................................................................................97
12.20 Expected wye input.................................................................................................................98
12.21 Electrical connection diagram.............................................................................................. 99
Contents
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1 About this document
1.1 Function of this document
The document is only applicable for this EVSE: Terra HP Generation 3, including the
variants and options listed in section 12.1.
The document gives the information that is necessary to install the EVSE.
1.2 Target group
The document is intended for qualified installation persons.
For a description of the required qualifications, refer to section 2.3.
1.3 Revision history
Version Date Description
001 March 2021 Initial version
002 May 2021 Updates
003 July 2021 Updates
004 November 2021 Updates
1.4 Language
The original instructions of this document are in English (EN-US). All other language
versions are translations of the original instructions.
1.5 Illustrations
It is not always possible to show the configuration of your EVSE. The illustrations in
this document show a typical setup. They are for instruction and description only.
1.6 Units of measurement
SI units of measurement (metric system) are used. If necessary, the document
shows other units between parentheses () or in separate columns in tables.
1.7 Typographical conventions
The lists and steps in procedures have numbers (123) or letters (abc) if the sequence
is important.
1.8 How to use this document
1. Make sure that you know the structure and contents of this document.
2. Read the safety chapter and make sure that you know all the instructions.
About this document
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3. Do the steps in the procedures fully and in the correct sequence.
4. Keep the document in a safe location that you can easily access. This document
is a part of the EVSE.
1.9 General symbols and signal words
Signal word Description Symbol
Danger If you do not obey the instruction, this
can cause injury or death.
Refer to section
1.10.
Warning If you do not obey the instruction, this
can cause injury.
Refer to section
1.10.
Caution If you do not obey the instruction, this
can cause damage to the EVSE or to
property.
Note A note gives more data, to make it easier
to do the steps, for example.
- Information about the condition of the
EVSE before you start the procedure.
- Requirements for personnel for a proce-
dure.
- General safety instructions for a proce-
dure.
- Information about spare parts that are
necessary for a procedure.
- Information about support equipment
that is necessary for a procedure.
- Information about supplies (consuma-
bles) that are necessary for a procedure.
- Make sure that the power supply to the
EVSE is disconnected.
About this document
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Signal word Description Symbol
- Electrotechnical expertise is required,
according to the local rules.
- Alternating current supply
Note: It is possible that not all symbols or signal words are present in
this document.
1.10 Special symbols for warnings and dangers
Symbol Risk type
General risk
Hazardous voltage that gives risk of electrocution
Risk of pinching or crushing of body parts
Rotating parts that can cause a risk of entrapment
Hot surface that gives risk of burn injuries
Note: It is possible that not all symbols are present in this document.
1.11 Related documents
Document name Target group
Product data sheet All target groups
Installation manual Qualified installation person
User manual Owner
About this document
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