ABB Terra 94 User manual

Installation manual
Terra 94/124/184
© 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.
2BCM.S1102.0-EN | 001

Contents
1 About this document.......................................................................... 6
1.1 Function of this document...................................................................................................... 6
1.2 Target group...............................................................................................................................6
1.3 Revision history..........................................................................................................................6
1.4 Language.....................................................................................................................................6
1.5 Illustrations.................................................................................................................................6
1.6 Units of measurement..............................................................................................................6
1.7 Typographical conventions..................................................................................................... 6
1.8 How to use this document...................................................................................................... 6
1.9 General symbols and signal words.........................................................................................7
1.10 Special symbols for warnings and dangers......................................................................... 8
1.11 Related documents................................................................................................................... 8
1.12 Manufacturer and contact data..............................................................................................8
1.13 Abbreviations............................................................................................................................. 9
1.14 Terminology................................................................................................................................9
1.15 Orientation agreements.........................................................................................................10
2 Description......................................................................................... 11
2.1 Type plate.................................................................................................................................. 11
2.2 Intended use..............................................................................................................................11
2.3 Working principles...................................................................................................................12
2.3.1 Terra 94, 124 and 184 CC and CJ...........................................................................12
2.3.2 Terra 94, 124 and 184 C.......................................................................................... 13
2.4 Overview.................................................................................................................................... 14
2.4.1 Overview of the system......................................................................................... 14
2.4.2 Overview of the EVSE, outside..............................................................................15
2.4.3 Overview of the EVSE, inside................................................................................ 16
2.5 Options.......................................................................................................................................17
2.5.1 EV charge cable, Combo 2......................................................................................17
2.5.2 EV charge cable, CHAdeMO...................................................................................17
2.5.3 Integrated payment terminal - CCV.....................................................................17
2.6 External residual-current device........................................................................................... 18
3 Safety.................................................................................................. 19
3.1 Liability.......................................................................................................................................19
3.2 General safety instructions....................................................................................................19
3.3 Required qualifications for the installation engineer.......................................................19
3.4 Personal protective equipment............................................................................................20
3.5 Safety instructions during installation............................................................................... 20
Contents
BCM.S1102.0-EN | 001 3

3.6 Safety instructions during transport...................................................................................21
3.7 Safety instructions for earthing............................................................................................21
3.8 Signs on the EVSE.................................................................................................................... 21
3.9 Discard parts or the EVSE...................................................................................................... 22
4 Transport............................................................................................23
4.1 Transport the EVSE to the site..............................................................................................23
4.2 Transport the EVSE on the site.............................................................................................23
4.2.1 Hoist the cabinet.....................................................................................................23
4.2.2 Move the cabinet with a forklift truck................................................................ 24
5 Installation......................................................................................... 25
5.1 General installation procedure............................................................................................. 25
5.2 Site preparation.......................................................................................................................25
5.2.1 Prepare the site....................................................................................................... 25
5.2.2 Control the space and airflow around the cabinet.......................................... 26
5.3 Prepare the foundation.......................................................................................................... 26
5.3.1 Prepare the foundation - general procedure.....................................................26
5.3.2 Prepare a standard prefab foundation...............................................................26
5.3.3 Prepare a custom foundation...............................................................................27
5.4 Unpacking................................................................................................................................. 27
5.4.1 Unpacking procedure.............................................................................................27
5.4.2 Do a check on the transport sensors.................................................................. 27
5.4.3 Remove the cabinet from the pallet....................................................................28
5.5 Mechanical installation...........................................................................................................28
5.5.1 Mechanical installation procedure...................................................................... 28
5.5.2 Open the cable inlet and remove the cable gland............................................ 28
5.5.3 Guide the cables through the opening in the cable guide plate................... 29
5.5.4 Install the cabinet on the foundation................................................................. 29
5.6 Electrical installation.............................................................................................................. 30
5.6.1 Electrical installation procedure..........................................................................30
5.6.2 Connect the wires of the AC input cable............................................................30
5.6.3 Connect the PE wire................................................................................................31
5.6.4 Connect the enclosure to the earth.....................................................................32
5.6.5 Connect the Ethernet cable.................................................................................. 32
5.7 Prepare for commissioning................................................................................................... 33
6 Access to parts.................................................................................. 34
6.1 Open the doors........................................................................................................................ 34
6.2 Close the doors........................................................................................................................34
6.3 Remove the border covers.....................................................................................................35
6.4 Install the border covers........................................................................................................ 35
Contents
4BCM.S1102.0-EN | 001

7 Troubleshooting................................................................................ 37
7.1 Troubleshooting procedure...................................................................................................37
8 Technical data....................................................................................38
8.1 EVSE type.................................................................................................................................. 38
8.2 Parts included in the delivery................................................................................................ 38
8.3 General specifications............................................................................................................39
8.4 Required tools for installation..............................................................................................39
8.5 Torque specifications............................................................................................................ 40
8.6 Ambient conditions................................................................................................................ 40
8.7 Mass and center of gravity....................................................................................................40
8.8 Noise level.................................................................................................................................40
8.9 Transport specifications........................................................................................................41
8.10 Dimensions............................................................................................................................... 41
8.10.1 General dimensions................................................................................................ 41
8.10.2 Cable slack................................................................................................................ 41
8.10.3 Floor space requirements..................................................................................... 42
8.10.4 Prefab foundation...................................................................................................43
8.10.5 Custom foundation................................................................................................44
8.11 Logic interface specifications.............................................................................................. 44
8.12 AC input specifications.......................................................................................................... 45
8.12.1 General AC input specifications...........................................................................45
8.12.2 AC input cable..........................................................................................................45
8.12.3 Terra 94.....................................................................................................................45
8.12.4 Terra 124................................................................................................................... 46
8.12.5 Terra 184...................................................................................................................46
8.13 DC output specifications.......................................................................................................46
8.13.1 General specifications........................................................................................... 46
8.13.2 Terra 94.....................................................................................................................46
8.13.3 Terra 124................................................................................................................... 48
8.13.4 Terra 184...................................................................................................................50
8.14 Power consumption................................................................................................................ 51
8.14.1 General specifications............................................................................................51
8.14.2 Terra 94..................................................................................................................... 51
8.14.3 Terra 124....................................................................................................................51
8.14.4 Terra 184................................................................................................................... 52
8.15 Current peaks during the start of a charge cycle..............................................................52
Contents
BCM.S1102.0-EN | 001 5

1 About this document
1.1 Function of this document
The document is only applicable for this EVSE (Terra x4), including the variants and
options listed in section 8.1 .
The document gives the information that is necessary to install the EVSE.
1.2 Target group
The document is intended for qualified installation engineers.
For a description of the required qualifications, refer to section 3.3 .
1.3 Revision history
Version Date Description
001 Initial version
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.
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.
About this document
6BCM.S1102.0-EN | 001

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.
- Electrotechnical expertise is required,
according to the local rules.
Note: It is possible that not all symbols or signal words are present in
this document.
About this document
BCM.S1102.0-EN | 001 7

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
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 engineer
User manual Owner
Service manual Qualified service engineer
Declaration of conformity (CE) All target groups
1.12 Manufacturer and contact data
Manufacturer
ABB EV Infrastructure
Heertjeslaan 6
2629 JG Delft
The Netherlands
Contact data
The local representative of the manufacturer can give you support on the EVSE. You
can find the contact data here: https://new.abb.com/
About this document
8BCM.S1102.0-EN | 001

1.13 Abbreviations
Abbreviation Definition
AC Alternating current
CAN Controller area network
CPU Central processing unit
DC Direct current
EMC Electromagnetic compatibility
EV Electric vehicle
EVSE Electric vehicle supply equipment
MiD Measuring Instruments Directive
NFC Near field communication
NoBo Notified body
OCPP Open charge point protocol
PE Protective earth
PPE Personal protective equipment
RFID Radio-frequency identification
Note: It is possible that not all abbreviations are present in this
document.
1.14 Terminology
Term Definition
Network operating center
of the manufacturer
Facility of the manufacturer to do a remote check on
the correct operation of the EVSE
Cabinet Enclosure of the EVSE, including the components on
the inside
CHAdeMO Japanese DC fast charging method for electric vehicles
Contractor Third party that the owner or site operator hires to do
engineering, civil and electrical installation work
Grid provider Company that is responsible for the transport and dis-
tribution of electricity
Local rules All rules that apply to the EVSE during the entire lifecy-
cle of the EVSE. The local rules also include the national
laws and regulations.
Open charge point proto-
col
Open standard for communication with charge sta-
tions
Owner Legal owner of the EVSE
About this document
BCM.S1102.0-EN | 001 9

Term Definition
Site operator Entity that is responsible for the day-to-day control of
the EVSE. The site operator does not have to be the
owner.
User Owner of an EV, who uses the EVSE to charge the EV
Note: It is possible that not all terms are present in this document.
1.15 Orientation agreements
D
C
B
X
Z
Y
A
A Front side: face forward to the
EVSE during normal use
B Left side
C Right side
D Rear side
X X-direction (positive is to the right)
Y Y-direction (positive is rearward)
Z Z-direction (positive is upward)
About this document
10 BCM.S1102.0-EN | 001

2 Description
2.1 Type plate
IP54
SN: XXXX-XXX-XXXX-XXX
Part number XXXXXXXXXX
Prod. date XX XXXX XXXXXXXXXXXX
XX XXXXX XX
FOR USE WITH ELECTRICAL VEHICLES
Input xxxV x+PE-
DC Input xxx-xxxV Max xxxA
DC Output 1 CCS2 xxx-xxxV Max xxxA
DC Output 2 CHAdeMO xxx-xxxV Max xxxA
Max x.xkW/xxHz
DC AUX xxV xA
George Hintzenweg 81,
3068 AX Rotterdam,
The Nederlands
MADE IN ITALY www.abb.com
Weight XXX Kg
XXXXXXXXXX
XXXX-XXX-XXXX-XXX
A
B
C
D
E
G
H
I
J
F
K
L
M
A Manufacturer
B Serial number
C Part number of the EVSE
D Production date
E Internal product code (for the
manufacturer)
F Full EVSE type
G EVSE mass
H EVSE rating
I Address of the manufacturer
J CE mark
K Barcode with the serial number of
the EVSE
L Barcode with the part number of
the EVSE
M Additional EVSE rating data
Note: Find the type plate on your EVSE to see the applicable data. Refer
to section 2.4.2 .
2.2 Intended use
The EVSE is intended for the DC charging of EVs. The EVSE is intended for indoor or
outdoor use.
The properties of the electrical grid, the ambient conditions and the EV must
comply with the technical data of the EVSE. Refer to chapter
8 .
Only use the EVSE with accessories that the manufacturer provides and that obey
the local rules.
Description
BCM.S1102.0-EN | 001 11

Danger:
General risk
• If you use the EVSE in any other way than described in the related
documents, you can cause death, injury and damage.
• Use the EVSE only as intended.
2.3 Working principles
2.3.1 Terra 94, 124 and 184 CC and CJ
A
S
R
Q
T
U V N O
XX
G
G
G
G
G
G
F
K
K
L
L
ON
B D EC H JI
H I
J
W
P
M
1
1
2
A AC input cable
B Manual switch
C EMC filter
D AC contactor
E Residual-current device and
breaker
F Power module matrix
G Power module
H DC filter
I DC contactor
J DC fuse
K Overcorrect protection device
L Charge cable
M Interlink contactor
N Insulation management interface
O Charge protocol interface
P Surge-protection device
Q Residual-current device
R Heater
S Auxiliary power supply
T Cabinet controller board
U Power bridge
V Touchscreen
W Cooling fan
X LED for the illumination of the
exterior of the EVSE
1 CAN bus signal 1
2 CAN bus signal 2
• Black and bold lines: power connection
• Black and thin lines: auxiliary power connection
• Green lines: CAN bus
• Purple lines: control signal or monitoring signal
Description
12 BCM.S1102.0-EN | 001

Note: For Terra 94, the second array of three power modules is empty.
2.3.2 Terra 94, 124 and 184 C
A
R
Q
P
S
T U
W
G
G
G
G
G
G
F
KL
NM
B D EC H JI
V
O
2
1
1
A AC input cable
B Manual switch
C EMC filter
D AC contactor
E Residual-current device and
breaker
F Power module matrix
G Power module
H DC filter
I DC contactor
J DC fuse
K Overcurrent protection device
L Charge cable
M Insulation management interface
N Charge protocol interface
O Surge-protection device
P Residual-current device
Q Heater
R Auxiliary power supply
S Cabinet controller board
T Power bridge
U Touchscreen
V Cooling fan
W LED for the illumination of the
exterior of the EVSE
1 CAN bus signal 1
2 CAN bus signal 2
• Black and bold lines: power connection
• Black and thin lines: auxiliary power connection
• Green lines: CAN bus
• Purple lines: control signal or monitoring signal
Note: For Terra 94, the second array of three power modules is empty.
Description
BCM.S1102.0-EN | 001 13

2.4 Overview
2.4.1 Overview of the system
B D E C
F
A
A EV
B Parking space
C EVSE
D AC input cable
E Power distribution board
F EV charge cable
Part Function
EV The EV of which the batteries need to be charged
EVSE Refer to section 2.4.2 .
Parking space Location for the EV during the charge session
AC input cable To supply the electrical energy to the EVSE
Power distribution board To connect the EVSE to the AC grid input
EV charge cable To conduct the charge from the EVSE to the EV
Description
14 BCM.S1102.0-EN | 001

2.4.2 Overview of the EVSE, outside
N
J
K
I
H
G
F
A
B
C
D
M
L
C
E
A Left door
B Type plate
C Air inlet
D Cover on the air outlet
E Border cover
F EV charge cable outlet and holder
(1x or 2x)
G Plate over the RFID reader and the
integrated payment terminal
H Emergency stop button
I Touchscreen
J Front door
K Enclosure
L Antenna
M Right door
N Air outlet
Part Function
Front, left and right door To give authorized personnel access to the inside of
the EVSE
Type plate To show the identification data of the EVSE. Refer to
section 2.1 .
Air inlet and outlet To let cooling air in and out. The airflow makes sure
that the parts on the inside of the EVSE do not become
too hot.
Cover on the air outlet To prevent a blockage of the air outlet
Border cover To cover the lower part of the EVSE
EV charge cable outlet and
holder
To connect and hold the EV charge cable. Refer to sec-
tion 2.5 .
RFID reader To read the information from an RFID card
Payment terminal To pay for the charge session
Emergency stop button To stop the EVSE when there is an emergency
Touchscreen To control and monitor the charge session
Description
BCM.S1102.0-EN | 001 15

Part Function
Enclosure To reduce the accessibility of unqualified persons to
the inside of the EVSE
Antenna To send and receive wireless 2G, 3G and 4G signals
2.4.3 Overview of the EVSE, inside
H
G
F
A
B
C
D
E
A Main breaker 2
B Main breaker 1
C PE busbar
D Surge protection device switch
E Ethernet connection
F Cable guide plate
G Manual switch
H Auxiliary power supply breaker
Part Function
Main breaker 2 To connect or disconnect the power modules group 2
Main breaker 1 To connect or disconnect the power modules group 1
PE busbar To connect the PE cable
Surge protection device
switch
Breaker to protect the surge protection device, always
in the on position
Ethernet connection Connection for the Ethernet cable
Cable guide plate Plate with openings for the AC input cable and the
Ethernet cable
Manual switch To connect or disconnect the AC power input
Auxiliary power supply
breaker
To connect or disconnect the AC power input to or
from the auxiliary power for the control circuit
Description
16 BCM.S1102.0-EN | 001

2.5 Options
2.5.1 EV charge cable, Combo 2
A EV charge cable
2.5.2 EV charge cable, CHAdeMO
A EV charge cable
2.5.3 Integrated payment terminal - CCV
Description
BCM.S1102.0-EN | 001 17

2.6 External residual-current device
The manufacturer does not supply an external residual-current device. If an external
residual-current device is required because of local rules, this section helps you to
select the correct device.
Situation: the local rules require an immunity for short current peaks over PE
during the EV charging process
At the start of the EV charge cycle, a relay switches and engages the AC input power
to the power modules. Incidental current peaks can occur. For the specifications of
the current peaks, refer to section
8.15 .
A combination of these factors is the source of these current peaks:
• Asynchronous engagement of the phases in the relay
• The electrical capacity of the AC input power part of the EVSE
The amplitude of the current peaks can change. These factors are the source of the
differences:
• The location of the EVSE
• The power grid
• The earth impedance
Description
18 BCM.S1102.0-EN | 001

3 Safety
3.1 Liability
The manufacturer is not liable to the purchaser of the EVSE or to third parties for
damages, losses, costs or expenses incurred by the purchaser or third parties if any
target group mentioned in the related documents does not obey the rules below:
• Obey the instructions in the related documents. Refer to section 1.11 .
• Do not misuse or abuse the EVSE.
• Only make changes to the EVSE, if the manufacturer approves in writing of the
changes.
This EVSE is designed to be connected to and to communicate information and
data via a network interface. It is the sole responsibility of the owner to provide and
continuously ensure a secure connection between the EVSE and the network of the
owner or any other network.
The owner shall establish and maintain any appropriate measures (such as - but not
limited to - the installation of firewalls, application of authentication measures,
encryption of data and installation of anti-virus programs) to protect the EVSE, the
network, its system and the interface against any kind of security breaches,
unauthorized access, interference, intrusion, leakage and/or theft of data or
information.
The manufacturer is not liable for damages and/or losses related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft of
data or information.
3.2 General safety instructions
• This document, the related documents and the warnings included do not
replace your responsibility to use your common sense when you do work on the
EVSE.
• Only do the procedures that the related documents show and that you are
qualified for.
• Obey the local rules and the instructions in this manual. If the local rules
contradict the instructions in this manual, the local rules will apply.
If and to the extent permitted by law, in case of inconsistency or contradiction,
between any requirements or procedure contained in this document and any
such local rules, obey the stricter between the requirements and procedures
specified in this document and the local rules.
3.3 Required qualifications for the installation engineer
• The qualified installation engineer fully knows the EVSE and its safe installation.
• The installation engineer is qualified to work on high-voltage and high-current
electrical installations.
Safety
BCM.S1102.0-EN | 001 19

• The qualified installation engineer obeys all local rules and the instructions in
the installation manual.
• It is the responsibility of the owner of the EVSE to make sure that all qualified
installation engineers obey the local rules, the installation instructions, and the
specifications of the EVSE.
3.4 Personal protective equipment
Symbol Description
Protective clothing
Safety gloves
Safety shoes
Safety glasses
3.5 Safety instructions during installation
Preliminary requirements
1. •
• Do not use adaptors or conversion adapters.
• Do not use cord extension sets.
• Make sure that there is no voltage on the AC input cables during the complete
installation procedure.
• Keep unqualified personnel at a safe distance during installation.
• Only use electrical wires of sufficient gauge and insulation to handle the rated
current and voltage demand.
• Make sure that the load capacity of the grid is in accordance with the EVSE.
• Earth the EVSE correctly. Refer to section 3.7 .
• Make sure that the wiring inside the EVSE is protected from damage and cannot
get trapped when you open or close the cabinet.
• Make sure that water cannot enter the cabinet.
• Protect the EVSE with safety devices that the local rules specify.
Safety
20 BCM.S1102.0-EN | 001