ABB HP CP500, Installation Manual

Page 1: ...Installation manual Terra HP Generation 3 CE 350 kW Static DC system Copyright ABB All rights reserved ...

Page 2: ...Copyright All rights to copyrights registered trademarks and trademarks reside with their respective owners Copyright ABB EV Infrastructure All rights reserved 2 9AKK107992A6488 EN 004 ...

Page 3: ...eneral 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 Identifier labels on the EVSE EN 17186 norm 17 2 10 Discard the EVSE or parts of the EVSE 18 2 11 Cyber security 1...

Page 4: ...ection and transport 32 5 1 Transport the EVSE to the site 32 5 2 Inspect the EVSE on delivery 32 5 3 Do a check on the transport sensors 32 5 4 Unpack the EVSE 32 5 5 Transport the EVSE on the site 33 5 5 1 General transport procedure 33 5 5 2 Tilt the charge post to the vertical position 33 5 5 3 Move the cabinet with a forklift truck 34 5 5 4 Hoist the cabinet 35 5 6 Remove the cabinet from the...

Page 5: ...log CAN cables between the primary and secondary power cabinet 50 7 8 Connect the control cable for the tilt sensors to the primary power cabinet option 52 7 9 Connect the control cable for the tilt sensors to the secondary power cabinet option 53 8 Electrical installation of the charge post 55 8 1 General procedure 55 8 2 Connect the PE wire 55 8 3 Connect the DC power input cables 56 8 4 Connect...

Page 6: ...2 7 DC output specifications 76 12 8 Logic interfaces specifications 76 12 9 Current peaks during the start of a charge session DC output 77 12 10 Mass and center of gravity 77 12 10 1 Mass 77 12 10 2 Center of gravity power cabinet 77 12 10 3 Center of gravity charge post 78 12 11 Tilt sensor specifications option 78 12 12 Ambient conditions 78 12 13 Noise level 79 12 14 Torque specifications 79 ...

Page 7: ... the power cabinet 97 12 19 2 DC power installation cables 97 12 19 3 PE cable 98 12 19 4 AC auxiliary power cables 98 12 19 5 Interlock and DC guard cables 99 12 19 6 CAN cables 99 12 19 7 Cable for the tilt sensor control 100 12 19 8 Ethernet cable 100 12 20 Electrical connection diagram 101 Contents 9AKK107992A6488 EN 004 7 ...

Page 8: ...ment 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...

Page 9: ...ou 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...

Page 10: ...e 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 installa...

Page 11: ...13 Abbreviations Abbreviation Definition AC Alternating current BESS Battery energy storage system 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 eart...

Page 12: ...ractor 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 fo...

Page 13: ... C 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 9AKK107992A6488 EN 004 13 ...

Page 14: ...nd 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 2...

Page 15: ...y the safety instructions that apply to the hoisting equipment or the forklift truck Put on the correct personal protective equipment Refer to section 2 4 2 6 Safety instructions during installation Preliminary requirements 1 Installation engineer Make sure that there is no voltage on the AC input cables during the complete installation procedure Keep unqualified personnel at a safe distance durin...

Page 16: ...onal protective equipment Refer to section 2 4 2 7 Safety instructions for earthing Preliminary requirements Make sure that the EVSE is connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the product Make sure that the connections to the EVSE comply with all ap...

Page 17: ...dentifier labels help EV owners to select the correct EV charge connector for their EV or the correct charger socket for the EV charge cable of the EV These labels for Identification of vehicles and infrastructures compatibility are defined by the European Directive 2014 94 EU Alternative Fuels Infrastructure AFI based on the EN 17186 norm The identifier labels must be in these locations On each c...

Page 18: ...cal community waste collection point for recycling For more information contact the Government Waste Disposal department in your country 2 11 Cyber security Note This topic is valid for a wired Ethernet connection This product is designed to be connected to and to communicate information and data via a network interface It is the Owner s sole responsibility to provide and continuously ensure a sec...

Page 19: ...plate XX XXXXXX XX SAP PN XXXXXXXXXXXX GLOBAL ID XXXXXXXXXX SN XXXX XXX XXXX XXX FOR USE WITH ELECTRICAL VEHICLES XXXX xxx xxxV MAX XXXA XXXXX xxx xxxV XW PE XXXXX XXXX xxx xxxV XXXXX XXXX xxx xxxV XXX x xkW xxHz XXXX xxxA XXXX xxxA XX XXX xxV xA ABB B V George Hintzenweg 81 3068 AX Rotterdam The Nederlands VDE XXXXxxxx Class X xxx xx XX XXXXX x XX XXXXX x MADE IN ITALY Prod date xx xxxx Weight XX...

Page 20: ...The EVSE is an arrangement of these parts Substation Power cabinet Charge post An arrangement can have one or more power cabinets and one or more charge posts For the specifications of the configuration in this manual refer to section 3 4 3 4 Working principle Note For a detailed overview of all electrical connections refer to section 12 20 IMT I IBT I EMC Filter EMC Filter C CCB F IMI CPI A D BB ...

Page 21: ... E Power module x3 F EV charge cable Lines Description AC input power connections DC power connections Control lines general 3 5 Overview and functions 3 5 1 Power cabinet outside E F D B A C A Plinth cover B Air outlet C Type plate D Door E Air inlet 4x F Enclosure Description 9AKK107992A6488 EN 004 21 ...

Page 22: ...er cables Cable inlet A plate with openings for cables PE busbar To connect PE cables AC power connector To connect to the AC input power cable Main switch To connect or disconnect the AC power X 10 terminal block To connect to the AC auxiliary power cable X 8 terminal block To connect the interlock DC guard and CAN cables CAN2FIBER device To connect the optical CAN cable Tilt sensor option To det...

Page 23: ...ration 3 outside C D E F G B A J M L I J K H N A EV charge cable B RFID reader and the payment terminal option C Connector holder D Touchscreen E Door F Top light G Side LED strips H Cable retraction system I Enclosure J Air inlet and outlet K Type plate L Antenna M Hoisting points N Plinth cover Description 9AKK107992A6488 EN 004 23 ...

Page 24: ...ge cables DC power busbars To connect the DC power cables Cable gland plates Glands for the cables to the charge post PE busbar To connect the PE wire Q1 RCD Residual current circuit breaker to connect or discon nect the AC auxiliary power to the charge post X 10 terminal block To connect the AC auxiliary power cable X 20 terminal block To connect the interlock and DC guard cable CAN2FIBER device ...

Page 25: ...l 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 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...

Page 26: ...om the power cabinets to the charge post This power supply is not included in the scope of ABB EV Infrastructure ABB EV Infrastructure recommends to use an uninterruptible power supply It is possible to install tilt sensors afterwards Ask ABB EV Infrastructure Refer to section 1 12 Example An incident such as a heavy duty vehicle that crashes into the charge post can open the tilt sensor Example o...

Page 27: ...of extra items plan the installation of these items Examples External residual current device Refer to section 3 6 Options Refer to section 3 7 4 2 Prepare the site 1 Make sure that the design of the site complies with these specifications The length of the charge cables is sufficient for connection to the charge inlet of the EV For the length and cable reach of the charge cables refer to section ...

Page 28: ...ts Refer to section 12 16 2 Make sure that the air flow inlet and outlet cannot get blocked Think of snow or objects 4 4 Prepare the foundation 4 4 1 Prepare the foundation general procedure 1 Select the correct foundations according to the ground conditions 2 Prepare the foundation for the power cabinets Type Procedure Prefab concrete foundation Refer to section 4 4 2 Custom foundation Refer to s...

Page 29: ...tion with gravel or another substance to prevent rodents to enter the cabinet 4 4 3 Prepare a custom foundation for the power cabinet Preliminary requirements Custom foundation Refer to section 12 17 2 Procedure 1 Make the custom foundation Caution Make sure that the top surface of the foundation is above the ground level to prevent intrusion of water 2 Guide the cables into the holes C1 to C7 of ...

Page 30: ...for the DC power cables Holes B entrance cable conduit for the CAN interlock and DC guard cables from the power cabinet Holes C entrance cable conduit for the AC auxiliary power and PE cables from the power cabinet Holes D entrance cable conduit for the DC power cables Holes E exit cable conduit for the CAN interlock and DC guard cables Holes F exit cable conduit for the AC auxiliary power and PE ...

Page 31: ...e foundations For the relation between the cables and the holes refer to section 12 17 4 3 Install the foundation in the hole 4 Put the cables through the openings in the foundation Apply the full cable slack For the cable slack refer to section 12 15 5 Fill the foundation with gravel or another substance to prevent rodents to enter the cabinet C1 C3 C4 C2 Pre installation 9AKK107992A6488 EN 004 3...

Page 32: ...sensors 1 Do a check on the sensors A that record the shocks during transport 2 Do a check on the sensors B that record the maximum tilt during transport 3 If the sensors A show a red indication or the sensors B show a tilt that is too high do these steps a Refuse the delivery of the EVSE b Make a note on the delivery receipt c Within three days of the delivery ask the transport company for an ins...

Page 33: ...e vertical position Refer to section 5 5 2 Move the charge post with a forklift truck Refer to section 5 5 3 Hoist the charge post Refer to section 5 5 4 5 5 2 Tilt the charge post to the vertical position Preliminary requirements 1 The charge post is in the horizontal position 2 The charge post is unpacked Refer to section 5 4 Hoisting equipment including cables swivel eye bolts or bolts with lif...

Page 34: ...ked Refer to section 5 4 Forklift truck Refer to section 12 3 Warning Risk of pinching or crushing the cabinet is heavy Make sure that the forklift truck can lift the cabinet safely Obey the safety instructions that apply to the forklift truck Take into account the mass the dimensions and the center of gravity of the EVSE Refer to sections 12 10 and 12 15 Caution Do not drop the cabinet Procedure ...

Page 35: ...e EVSE Refer to sections 12 10 and 12 15 Caution Do not drop the cabinet Make sure that there are no dynamic forces on the hoisting points Make sure that the weight is equally distributed between the hoisting points Procedure 1 Install the swivel eye bolts or bolts with lifting loops A 2 Connect the cables B of the hoisting equipment to the swivel eye bolts or bolts with lifting loops 3 Move the c...

Page 36: ...Procedure 1 Remove the fasteners A 2 Discard the fasteners and the pallet Refer to section 2 10 A Inspection and transport 36 9AKK107992A6488 EN 004 ...

Page 37: ...e power cabinets Refer to section 7 1 4 Do the electrical installation of the charge post or the charge posts Refer to section 8 1 5 Prepare for commissioning Refer to section 9 6 2 Mechanical installation of the power cabinet 6 2 1 Install the power cabinet general procedure Preliminary requirements 1 The cabinet is above the foundation Procedure 1 Remove the plinth covers of the power cabinet Re...

Page 38: ... sure that there is no kink in the cables 2 Make sure that the holes in the cabinet A and the foundation B are aligned 3 Install the fasteners C and the washers 4 Tighten the fasteners to the correct torque For the specification refer to section 12 14 6 2 3 Open the cable inlets Preliminary requirements Open spanner Procedure 1 Open the door Refer to section 10 1 2 Loosen the fasteners A 3 Move th...

Page 39: ... 2 Guide the DC output cables C through the opening D 6 2 5 Close the cable inlets 1 Move the sliding plates B on the guidance plate to close the cable inlets and hold the cables C in place 2 Tighten the fasteners A 6 2 6 Install the front cover plate concrete foundation Preliminary requirements 1 The cabinet is installed on the foundation Four fasteners M10 Torque wrench C D A B A C B Installatio...

Page 40: ... the charge post a Remove the plinth covers of the charge post Refer to section 10 7 b Open the door of the charge post Refer to section 10 6 c Remove the protection plate of the charge post Refer to section 10 8 2 Remove the cable gland plates Refer to section 6 3 2 3 Guide the cables through the cable glands Apply the full cable slack Refer to section 3 5 6 4 Install the charge post on the found...

Page 41: ...ift truck Torque wrench Six fasteners M12 and washers Drop in anchors for easy installation and quality Procedure 1 Carefully lower the charge post on the foundation with a hoisting equipment or a forklift truck Refer to section 12 3 Caution Make sure that there is no kink in the cables 2 Make sure that the holes in the charge post A and the foundation B are aligned 3 Install the fasteners C and t...

Page 42: ...2 The protection cover is removed Screwdriver cross Set of open spanners Procedure 1 Install the nuts A of the cable glands over the cables 2 Install these parts a Cable gland plates B b Fasteners C 3 Tighten the nuts of the cable glands A C B Installation 42 9AKK107992A6488 EN 004 ...

Page 43: ...le Refer to section 7 3 c Install the AC covers 4 Connect the DC power cables a Remove the DC busbar cover Refer to section 10 3 b Connect the DC power cables Refer to section 7 4 c Install the DC busbar cover 5 Connect the AC auxiliary power interlock and DC guard and CAN cables a Connect the AC auxiliary power cable Refer to section 7 5 b Connect the interlock and DC guard cables Refer to sectio...

Page 44: ... compatible with the cable lug B 3 Attach the cable lugs to the end of the cables 4 On the bolt C install the toothed washer D the cable lug B and the contact washer E 5 Connect these cables to the busbar 1 PE cable of the AC input cable 2 Cable from the charge post 3 If there is a secondary power cabinet PE cable from the secondary power cabinets 4 Lightning protection 6 Install a toothed washer ...

Page 45: ...A 3 Attach the cable lugs to the end of the cables 4 Connect these cables 1 L1 C 2 L2 D 3 L3 E 5 Install the nuts and washers B on the busbar bolts 6 Tighten the nuts to the correct torque For the specification refer to section 12 14 7 4 Connect the DC power cables Preliminary requirements Torque wrench Wire cutter Wire stripper pliers DC power cables primary cabinet two positive two negative DC p...

Page 46: ...re that the cable lugs E are inversed 6 Install the nuts and washers on the connector block bolts 7 Tighten the nuts to the correct torque For the specification refer to section 12 14 7 5 Connect the AC auxiliary power cable in the primary power cabinet Preliminary requirements Torque screwdriver cross Wire cutter Wire stripper pliers Crimp pliers AC auxiliary power cable Refer to section 12 19 4 ...

Page 47: ... D grey to the terminal X10 4 H 5 Tighten the screws to the correct torque For the specification refer to section 12 14 7 6 Connect the interlock and DC guard cables 7 6 1 Connect the interlock and DC guard cables to the primary power cabinet Preliminary requirements Two interlock and DC guard cables Refer to section 12 19 5 Wire loop Note The illustration shows the terminal block X8 of the primar...

Page 48: ...round wire or shield mesh Earthing terminal PE H IL IN 1 X8 7 IL OUT 3 I IL OUT 1 X8 6 IL IN 3 J DC guard B GND X8 5 DC guard B GND K DC guard B X8 4 DC guard B 7 6 2 Connect the interlock and DC guard cables to the secondary power cabinet Preliminary requirements Interlock and DC guard cables Refer to section 12 19 5 18 17 16 19 21 22 20 24 23 15 14 13 12 11 10 9 8 7 6 5 4 X8 1 2 3 CanH_IN GND_CA...

Page 49: ...etween the terminals X8 10 and X8 11 G between the terminals X8 6 and X8 7 7 7 Connect the CAN cables 7 7 1 Connect the optical CAN cables between the charge post and the primary power cabinet Note The Rx and Tx lines must be swapped between the charge the post and the primary power cabinet Note For a detailed overview of all electrical connections refer to section 12 20 18 17 16 19 21 22 20 24 23...

Page 50: ... D connection Rx at D2 4 Tie the CAN cables together a Tighten the loops of the cables with cable ties b Make sure that the loop bend radius is sufficient to prevent damage to the cable core For the specification refer to section 12 19 6 7 7 2 Connect the analog CAN cables between the primary and secondary power cabinet Note Use the illustration below as a reference For the connection procedure re...

Page 51: ...8 17 16 19 21 22 20 24 23 15 14 13 12 11 10 9 8 7 6 5 4 18 17 16 19 21 22 20 24 23 15 14 13 12 11 10 9 8 7 6 5 4 PE CanH_IN GND_CAN_IN CanL_IN DC Guard B X8 Power Cabinet Primary DC Guard B GND IL_IN_3 IL_OUT_3 DC Guard A 2 DC Guard A 2 GND IL_IN_2 IL_OUT_2 DC Guard A 1 DC Guard A 1 GND IL_IN_1 IL_OUT_1 PE PE PE CanH_OUT CanL_OUT GND_CAN_OUT Internal USE Internal USE Internal USE Internal USE Inte...

Page 52: ...ke sure that the loop bend radius is sufficient to prevent damage to the cable core For the specification refer to section 12 19 6 7 8 Connect the control cable for the tilt sensors to the primary power cabinet option Preliminary requirements Torque screwdriver cross Wire cutter Wire stripper pliers Crimp pliers Control cable for the tilt sensors Refer to section 12 19 7 Ferrules Procedure 1 Strip...

Page 53: ...re number 4 to the terminal X1 7 O Rout wire H from the secondary power cabinet wire number 4 to the terminal X1 8 P 5 Tighten the screws to the correct torque For the specification refer to section 12 14 7 9 Connect the control cable for the tilt sensors to the secondary power cabinet option Preliminary requirements Torque screwdriver cross Wire cutter Wire stripper pliers Crimp pliers Control ca...

Page 54: ...er 2 to the terminal X2 4 L Rin wire E from the primary power cabinet wire number 3 to the terminal X2 5 M Rin wire F from the charge post wire number 3 to the terminal X2 6 N Rout wire G from the primary power cabinet wire number 4 to the terminal X2 7 O Rout wire H from the charge post wire number 4 to the terminal X2 8 P 5 Tighten the screws to the correct torque For the specification refer to ...

Page 55: ...o the charge post PE wire Refer to section 8 2 DC power cable Refer to section 8 3 AC auxiliary power cable Refer to section 8 4 Interlock and DC guard cable Refer to section 8 5 Optical CAN cable from the power cabinet Refer to section 8 6 Control cables for the tilt sensor option Refer to section 8 8 Ethernet cable Refer to section 8 7 4 Install the protection plate 5 Close and lock the door of ...

Page 56: ...t torque For the specification refer to section 12 14 8 3 Connect the DC power input cables Preliminary requirements Wire cutter Wire stripper pliers Spanner Torque wrench Torque screwdriver cross DC power cable Refer to section 12 19 2 Cable lugs Refer to section 12 4 Procedure 1 Cut the DC power cables A and B to make sure that the length is sufficient for connection at the DC busbars C and D 2 ...

Page 57: ... AC auxiliary power cable Ferrules Note The AC auxiliary power cable provides the control power to the charge post Procedure 1 Strip the insulation from the ends of the wires A to D For the specification refer to section 12 19 4 2 Crimp ferrules onto the end of the wires 3 Loosen the screws of the terminals E to H of the terminal block X 10 4 Connect these wires PE wire A green yellow to the termi...

Page 58: ...on 12 20 Preliminary requirements Torque screwdriver cross Interlock and DC guard cable Refer to section 12 19 5 Ferrules Procedure X20 4 3 1 2 5 6 7 8 9 10 EXT_Interlock_In EXT_Interlock_Out PE DC guard GND DC guard signal GND V V Rout Rin E D C B A Electrical installation of the charge post 58 9AKK107992A6488 EN 004 ...

Page 59: ... D DC guard A1 X20 9 DC guard signal E DC guard A1 GND X20 10 DC guard GND Note The colors of the cables can be different in your equipment The colors in the illsutration are used to clarify the explanation and to distinguish the different cables 8 6 Connect the optical CAN cable Note The Rx and Tx lines must be swapped between the charge the post and the power cabinet Note For a detailed overview...

Page 60: ...Rx at A100 4 Do not connect the two remaining fiber cables These fiber cables are spares 5 Tie the CAN cables together a Tighten the loops of the cables with cable ties b Make sure that the loop bend radius is sufficient to prevent damage to the cable core For the specification refer to section 12 19 6 8 7 Connect the Ethernet cable Preliminary requirements Ethernet cable with an RJ45 plug Refer t...

Page 61: ... 7 Ferrules Procedure 1 Strip the insulation from the ends of the wires A to D For the specification refer to section 12 19 7 2 Crimp ferrules onto the end of the wires 3 Loosen the screws of the terminal block X 20 4 Connect these wires V wire A grey to the terminal X 20 4 E V wire B blue to the terminal X 20 5 F Rin wire C green to the terminal X 20 6 G Rout wire D brown to the terminal X 20 7 H...

Page 62: ...atible connection If the EVSE has more than one connection type an EV of each type must be available The site operator or owner is available to receive instructions from the service engineer of the manufacturer 3 Make sure that this data is available Contact data of the contact person on site Address of the EVSE Site name Exact location of the EVSE longitude and latitude If there are more EVSEs on...

Page 63: ...or key Note There is one unique door key for each power cabinet Procedure 1 Turn the cover plate A 2 Insert the door key B 3 Turn the door key counterclockwise to unlock the door C 4 Pull the handle D 5 Turn the handle clockwise 6 Open the door 10 2 Remove the plinth covers of the power cabinet Preliminary requirements Screwdriver cross D A B C 1 4 2 3 5 6 Access to parts 9AKK107992A6488 EN 004 63...

Page 64: ... B 10 3 Remove the DC busbar cover Preliminary requirements Screwdriver cross Procedure 1 Remove the fasteners A 2 Remove the cover B 10 4 Remove the AC covers Preliminary requirements Screwdriver cross B A B A A B A Access to parts 64 9AKK107992A6488 EN 004 ...

Page 65: ...e sure that only qualified personnel has access to the door key Note There is one unique door key for each cabinet Procedure 1 Close the door A 2 Turn the handle B counterclockwise 3 Push the handle 4 Turn the door key C clockwise to lock the door 5 Remove the door key C 6 Turn the cover plate D to cover the keyhole C B A A C B 6 3 5 4 2 1 D Access to parts 9AKK107992A6488 EN 004 65 ...

Page 66: ...y for each charge post The door of the charge post is under some pressure to make sure that it closes watertight Procedure 1 Insert the door key A 2 Turn the door key counterclockwise to unlock the door B 3 Pull the handle C 4 Turn the handle clockwise 5 Open the door 10 7 Remove the plinth covers of the charge post Preliminary requirements Set of hex keys A 1 2 3 4 5 C B Access to parts 66 9AKK10...

Page 67: ...irements Screwdriver cross Procedure 1 Remove these parts Fasteners A Protection plate B 10 9 Close the door of the charge post Preliminary requirements Door key of the charge post Danger Hazardous voltage Make sure that only qualified personnel has access to the door key A A A B B B A Access to parts 9AKK107992A6488 EN 004 67 ...

Page 68: ... for each charge post Procedure 1 Close the door A 2 Turn the handle B counterclockwise 3 Push the handle 4 Turn the door key C clockwise to lock the door 5 Remove the door key C 5 4 3 2 1 A B Access to parts 68 9AKK107992A6488 EN 004 ...

Page 69: ...mpatible with the wire 2 Strip the insulation from the wire The stripped length must be the same as the length of the cavity of the cable lug 3 Insert the conductor of the wire into the cavity of the cable lug 4 Install the cable lug on the wire Use the crimp plier 11 2 Install a ferrule on a wire Preliminary requirements Wire cutter Wire stripper pliers Crimp plier Ferrule 1 2 2 B A Generic proce...

Page 70: ...e ferrule on the wire Use the crimp plier 11 3 Install insulating heatshrink tubing on a wire Preliminary requirements Heat gun Heatshrink tubing Procedure 1 Clean the part of the wire or the wire with the cable lug that you want to insulate 2 Cut a piece of heatshrink tubing Make sure that the length covers all electrical cables Use a diameter that is larger than the wire diameter 3 Install the p...

Page 71: ...pecification refer to section 12 14 4 Make sure that unused wires are protected and cannot touch metal parts 11 5 Connect a wire that has a ferrule Preliminary requirements Procedure 1 Loosen the screw of the connection on the terminal 2 Install the ferrule in the connection of the terminal 3 Tighten the screw to the correct torque For the specifications refer to section 12 14 4 Make sure that unu...

Page 72: ...k output power kW Examples HP CP500 C T HP Model Terra high power U CP500 Part charge post 500 A DC output V C EV charge cable connection one CCS connection HP 175 T HP Model Terra high power U Part power cabinet V 175 peak output power is 175 kW 12 2 Parts included in the delivery Parameter Specification Charge post Refer to the type plate Refer to section 3 2 Power cabinet Refer to the type plat...

Page 73: ... M10 for the charge post Thread M16 for the power cabinet Bolts Size M16 Hex keys Standard set of hex keys Open spanners Standard set of open spanners Torque socket wrench For the torque specifications refer to section 12 14 Screwdriver cross Size M5 8 mm 0 3 in Wire cutter Wire stripper pliers Crimp pliers 12 4 Required parts for installation Part Specification Fasteners and washers to connect th...

Page 74: ...input power M12 39 1 5 70 2 7 DC power M12 39 1 5 70 2 7 Charge post PE M8 22 0 9 40 1 6 M6 12 0 5 40 1 6 DC power M12 39 1 5 40 1 6 12 5 General specifications Parameter Specification Compliance and safety CE Ingress protection rating IP54 Technical data 74 9AKK107992A6488 EN 004 ...

Page 75: ... standards EN 61000 6 4 2007 A1 Emission standard for industrial environments Class A EN 61000 6 2 2005 Immunity for in dustrial environments If the power cabinet must comply with Class B residential install an external EMC filter Schaffner type FN 3359HV 400 99 To order this part give the global ID 6AGC079955 When this external EMC filter is installed the power cabinet complies with this standard...

Page 76: ...put current 308 A at 360 V AC Power factor at full load 0 97 Efficiency 94 at 20 load 94 at 20 load 8 for 90 kW output power 12 7 DC output specifications Parameter Specification Output voltage range 150 920 V DC Maximum output current 375 A DC one power cabinet 500 A DC two power cabinets Output power 175 kW up to 40 C 104 F one power cabinet 350 kW up to 40 C 104 F two power cabinets DC output c...

Page 77: ...rrent peak 60 A 12 10 Mass and center of gravity 12 10 1 Mass Parameter Specification kg lbs Mass of the power cabinet 1400 3086 5 Mass of the charge post 250 551 2 12 10 2 Center of gravity power cabinet X Z Y A A Center of gravity Parameter Specification mm in X 587 23 1 Y 407 16 0 Z 1068 42 1 Technical data 9AKK107992A6488 EN 004 77 ...

Page 78: ...t sensor specifications option Parameter Specification Tilt to disable the power from the low voltage source 10 12 12 Ambient conditions Parameter Specification Operation temperature 35 C to 55 C 31 F to 131 F Derating applies Storage 5 C to 40 C 41 F to 104 F RH 5 to 85 Environment IP54 rainproof Technical data 78 9AKK107992A6488 EN 004 ...

Page 79: ...6 Power cabinet nuts on the AC power busbars 30 266 Power cabinet screws in the terminal blocks 1 3 11 5 Power cabinet nuts on the DC power busbars 30 266 Charge post fasteners to the founda tion 80 708 Charge post fasteners on the PE busbar Between 33 and 44 Between 292 and 389 Charge post screws in the terminal blocks 1 3 11 5 DC input cable to the connector 30 265 5 M5 fasteners if not specifie...

Page 80: ...equired cable slack for the interlock and DC guard and CAN cables meas ured from the top of the foundation 2000 78 7 12 15 2 Charge post Parameter Specification mm in Width of the charge post X dimension 590 23 2 Depth of the charge post Y dimension 425 16 7 Height of the charge post Z dimension 2463 97 0 Required cable slack for the PE wire measured from the top of the founda tion 700 27 6 Requir...

Page 81: ...ification m ft Length of the charge cable with retrac tion system 5 3 9 8 Cable reach approximately 3 118 12 15 3 Height of user operable elements Z1 Z4 Z6 Z5 Z8 Z7 Z3 Z2 Parameter Specification mm in Z1 Advised maximum curb height 102 4 Z2 Bottom of the authentication cluster 750 or higher 29 5 Z3 CCS connector when holstered center of grip 775 30 5 Z4 CHAdeMO connector when hol stered center of ...

Page 82: ...equirements 12 16 1 Power cabinet Y2 Y1 X3 Y3 X2 X2 X1 A B C D E A Power cabinet X1 Total width required for the power cabinet X2 Space for air inlet on the side X3 Space to open the power cabinet door Y1 Total depth required for the power cabinet Y2 Space to open the power cabinet door Y3 Space for air outlet B Back to back configuration C Side by side configuration D Back to back configuration f...

Page 83: ...9 Parameter Specifications for power cabinets side by side mm in X2 0 0 Y3 100 per power cabinet 3 9 per power cabinet Parameter Specifications for power cabinets back to back mm in X2 100 per power cabinet 3 9 per power cabinet Y3 0 0 12 16 2 Charge post Y4 Y2 X1 X3 X2 X2 X5 X5 A X3 Y1 Y3 Y5 X4 Technical data 9AKK107992A6488 EN 004 83 ...

Page 84: ...rge post Y3 Maximum sideway reach of the wheelchair user Y4 Space required to open the door Y5 Required depth to open the side panel Parameter Specification mm in X1 1490 58 7 X2 450 17 7 X3 105 4 1 X4 800 31 5 X5 345 13 6 Y1 400 15 7 Y2 775 30 6 Y3 254 10 Y4 490 19 3 Y5 345 13 6 12 16 3 Charge post exceptions for bollards and other minor fixed obstacles Note The bollards or minor fixed obstacles ...

Page 85: ...anel Y2 Required depth to open the side panel Y3 Total required width to open side panels Y4 Space required to open the door Parameter Specification mm in X1 1190 46 8 X2 200 7 8 X3 105 4 1 X4 800 31 5 Y1 250 9 8 Y2 200 7 8 Y3 675 26 5 Y4 490 19 3 12 16 4 Distance requirements between power cabinet and charge post Parameter Specification m ft Maximum distance between the power cabinet and the char...

Page 86: ...lasticizer and waterproofing addi tive Concrete class C32 40 Exposure class CX4 and XD25 according to UNI 11104 2018 Dimensions side view Y5 a1 a1 Y4 Y1 Y2 Y3 Y8 Y7 Y9 Y10 Y11 Y12 Z2 Z1 Z3 a2 a2 D1 D2 Parameter Specification mm in Y1 120 4 72 Y2 930 36 6 Y3 120 4 72 Y4 928 36 5 Y5 870 34 3 Y6 1170 46 1 Y7 300 11 8 Y8 570 22 4 Technical data 86 9AKK107992A6488 EN 004 ...

Page 87: ... Z3 720 28 3 D1 8x diameter 160 6 30 D1 4x diameter 90 3 54 Parameter Specification α1 93 α2 90 D1 hole 3 tapered D2 hole 3 tapered Dimensions front view X3 a1 a1 X1 X2 Y8 Y7 Y9 Y10 Y11 Y4 Z1 Z2 a2 a2 R X5 X6 X4 Parameter Specification mm in X1 120 4 72 X2 120 4 72 Technical data 9AKK107992A6488 EN 004 87 ...

Page 88: ...X7 400 15 7 X8 625 24 6 X9 275 10 8 X10 775 30 5 X11 525 20 7 X12 1300 51 2 Z1 700 27 6 Z2 20 0 79 R all edges 3 0 1 Parameter Specification α1 93 α2 90 Dimensions top view Y4 Y9 Y7 Y2 Y1 Y3 X2 X1 X3 X10 X9 X11 X5 X6 X4 X7 X8 Y5 Y6 Y8 C A B Technical data 88 9AKK107992A6488 EN 004 ...

Page 89: ... 94 X10 800 1 31 5 0 1 X11 100 3 94 X12 100 3 94 Y1 250 9 84 Y2 670 26 4 Y3 250 9 84 Y4 60 2 3 Y5 1050 1 41 3 0 1 Y6 60 2 3 Y7 100 3 94 Y8 670 1 26 4 0 1 Y9 100 3 94 Y10 100 3 94 Parameter Specification A 4x T Fixx M16 depth 80 3 1 RVS B 4x T Fixx M10 depth 65 2 6 RVS C 4x T Fixx M10 depth 65 2 6 RVS Technical data 9AKK107992A6488 EN 004 89 ...

Page 90: ...shows the front side of the power cabinet Parameter Specification A 4x For M16 fasteners depth 60 2 4 Parameter Specification mm in X0 1170 46 1 X1 1050 41 3 X2 930 36 6 X3 60 2 4 X4 153 6 0 X5 409 16 1 X6 409 16 1 X7 138 5 4 X8 60 2 4 Y0 770 30 3 Y1 680 26 8 Y2 748 29 4 Y3 49 1 9 Y4 133 5 2 Technical data 90 9AKK107992A6488 EN 004 ...

Page 91: ...guard to the secondary power cabinet CAN interlock and DC guard to the primary power cabinet C3 CAN interlock and DC guard to the charge post None C4 AC auxiliary and PE to the charge post None C5 DC power to the secondary power cabinet None C6 DC power to the charge post None C7 DC power to the charge post DC power to the primary power cabinet 12 17 3 Charge post prefab concrete Foundation mass a...

Page 92: ...3 Z2 Z4 a1 Z5 Z6 Parameter Specification mm in X1 175 6 89 X2 640 25 2 Y1 220 8 66 Y2 157 5 6 20 Z1 30 1 2 Z2 500 19 7 Z3 200 7 87 Z4 162 5 6 40 Z5 282 5 11 1 Z6 428 16 9 Parameter Specification α1 3 Technical data 92 9AKK107992A6488 EN 004 ...

Page 93: ...00 39 4 Y1 125 4 92 Y2 150 5 91 Y3 150 5 91 Y4 1400 55 1 Y5 440 17 3 D1 diameter 125 4 92 D2 diameter 125 4 92 D3 diameter 60 2 36 Parameter Specification α1 3 Tube diameter for D1 125 119 mm 4 92 44 1 in Tube diameter for D2 125 119 mm 4 92 44 1 in Tube diameter for D3 60 56 mm 2 36 2 20 in Technical data 9AKK107992A6488 EN 004 93 ...

Page 94: ... post custom Y X6 X5 X4 X7 X3 X2 X1 Y2 Y3 Y4 Y6 Y5 Y1 Y1 A B B C Note The arrow shows the front side of the charge post Parameter Specification A 6x For M12 fasteners diameter 14 0 6 Parameter Specification mm in X0 580 22 8 X1 526 20 7 X2 45 1 8 X3 436 17 X4 100 3 9 X5 110 4 3 X6 170 6 7 X7 85 3 3 Technical data 94 9AKK107992A6488 EN 004 ...

Page 95: ... Y6 200 7 9 Cable conduit hole Maximum diameter mm in C1 60 2 4 C2 60 2 4 C3 126 5 0 C4 126 5 0 Function for cable conduit holes Cable conduit hole Cable conduit for these cables C1 AC auxiliary and PE C2 CAN interlock and DC guard C3 DC power C4 DC power Technical data 9AKK107992A6488 EN 004 95 ...

Page 96: ...ge post Note The arrows show the front side of the charge post and the power cabinets Cable conduit Cables C DC power D AC auxiliary power PE E CAN Interlock DC guard F AC power Cable conduit Maximum diameter mm in Small holes in the foundation of the power cabinet 90 3 54 Large holes in the foundation of the power cabinet 160 6 30 Technical data 96 9AKK107992A6488 EN 004 ...

Page 97: ...test voltage 4 kV Ambient temperature range 40 C to 80 C 40 F to 176 F Diameter of the PE conductor The same as the diameter of the phase conductors 12 19 2 DC power installation cables The below data are specific for the DC power cables between the power cabinet and the charge post Parameter Specification Type 1x Positive 1x negative cable Flexible Unshielded Number of cores 1 Cross section range...

Page 98: ...door use UV protected and oil resistant Minimum nominal voltage Uo U 600 1000 Vac Minimum test voltage 4 kV Ambient temperature range 40 C to 80 C 40 F to 176 F Diameter of the PE conductor The same as the diameter of the phase conductors 12 19 4 AC auxiliary power cables Parameter Specification Number of cores 4 Cross section range 2 5 mm 14 AWG Shielding No Conductor Bare copper fine wired brunc...

Page 99: ...ts Parameter Specification Number of cores 1 x 2 twisted and shielded pair Diameter 0 5 to 0 75 mm 20 to 18 AWG Shielding Tinned copper braid Conductor Fine strand copper wire Nominal voltage 600 1000 V AC Insulation PVC or other material that are serviceble for outdoor use and are UV protected Minimum test 1 5 kV Strip length 11 mm 0 43 in Table 3 Optical CAN cables between the power cabinet and ...

Page 100: ...erviceable for outdoor use and UV protected Minimum test 1 5 kV Strip lenght 11 mm 0 43 in 12 19 8 Ethernet cable Parameter Specification Type Shielded tinned copper braid Number of twisted pairs 4 x 2 Core identification Acc to DIN 47100 Cross section 0 5 0 75 mm Diameter 5 10mm Conductor Fine strand copper wire Insulation PVC that is serviceable for outdoor use UV protected and oil resistant Cha...

Page 101: ...2 1 PE X400 X402 DC DC X10 X8 POWER CABINET X324 AC Main Grid PE X10 X8 POWER CABINET X324 PE X400 X402 DC DC X10 X20 CHARGE POST SECONDARY PRIMARY CONDUIT CONDUIT 2 5mm GY 2 5mm BK 2 5mm BN 2 5mm GN YE Refer to next page Signal connection Charge Cabinet Charge Refer to next page Signal connection Charge Cabinet Charge CONDUIT TWO POWER CABINET AND ONE CHARGE POST PROJECT NAME 3Q38 ELECTRICAL CONN...

Page 102: ..._Interlock_In EXT_Interlock_Out PE X20 4 3 PE CanH_IN GND_CAN_IN CanL_IN DC Guard B 1 TX RX X8 A100 D2 2 5 6 7 8 9 10 DC guard GND DC guard signal GND V V Rout Rin TX RX Power Cabinet Primary DC Guard B GND IL_IN_3 IL_OUT_3 DC Guard A 2 DC Guard A 2 GND IL_IN_2 IL_OUT_2 DC Guard A 1 DC Guard A 1 GND IL_IN_1 IL_OUT_1 PE PE PE CanH_OUT CanL_OUT GND_CAN_OUT Internal USE Internal USE Internal USE Inte...

Page 103: ...Technical data 9AKK107992A6488 EN 004 103 ...

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