ABB Terra AC Series, Installation Manual

Page 1: ...Installation manual Terra AC Copyright 2020 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 BCM V3Y01 0 EN 001 ...

Page 3: ...scription 12 2 2 Intended use 12 2 3 Type plate 12 2 4 Working principle 13 2 5 Overview 14 2 5 1 Overview of the system 14 2 5 2 Overview of the EVSE outside 15 2 5 3 Overview of the EVSE inside 16 2 6 Options 17 2 6 1 Display 17 2 6 2 EV charge cable type 2 17 2 6 3 Socket type 2 17 2 6 4 EV charge cable type 1 18 2 6 5 3G 4G Communication 18 2 6 6 Load management 18 2 7 Control elements 19 2 7 ...

Page 4: ...edure 29 6 2 Install the mounting screws 29 6 3 Install the EVSE on the wall 30 7 Electrical installation 31 7 1 General electrical installation procedure 31 7 2 Insert the AC input cable 31 7 3 Connect the AC input cable 32 7 3 1 Connect the AC input cable 1 phase 32 7 3 2 Connect the AC input cable split phase North America 32 7 3 3 Connect the AC input cable 3 phase 33 7 3 4 Secure the cables 3...

Page 5: ...46 11 3 1 Protective device compliance Europe 46 11 3 2 Protective device compliance North America 47 11 4 Parts included in the delivery 47 11 5 General specifications 47 11 6 Required tools for installation 48 11 7 Ambient conditions 48 11 8 Requirements for the wall 48 11 9 Noise level 49 11 10 Dimensions 49 11 10 1 AC input with socket cable Type 2 49 11 10 2 AC input with EV charge cable 50 1...

Page 6: ... America 54 11 13 3 Ethernet cable specifications 55 11 13 4 RS485 cable specifications 55 11 13 5 Dry contacts input 55 11 13 6 Dry contacts output 56 11 13 7 EV charge cable specifications 56 11 14 AC output specifications 56 11 14 1 AC output specifications Europe 56 11 14 2 AC output specifications North America 57 11 15 Specific power consumption specifications 57 11 16 Torque specifications ...

Page 7: ...is 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 othe...

Page 8: ...his 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 procedure Information about spare parts that are nec essary for a procedure Information about support equipment that is neces...

Page 9: ...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...

Page 10: ... to do a remote check on the correct operation of the EVSE Cabinet Enclosure of the EVSE including the components on the inside Contractor Third party that the owner or site operator hires to do engi neering civil and electrical installation work Grid provider Company that is responsible for the transport and distribu tion of electricity Local rules All rules that apply to the EVSE during the enti...

Page 11: ...ientation 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 BCM V3Y01 0 EN 001 11 ...

Page 12: ...manufacturer provides or that obey the local rules The EVSE AC input is intended for a hardwired installation that complies with the applicable national regulations 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 to property Use the EVSE only as intended 2 3 Type plate xxxxxxx xxxxxxx xxxxxx xxx xxxx xxxxx IPXX ...

Page 13: ...see the applicable data Refer to section 2 5 2 2 4 Working principle RFID CPU 3G 4G IN OUT G H A B C D E F I L J K M N P O 1 1 3 4 4 4 4 4 4 4 2 3 2 A LEDs B Ethernet C WiFi D 3G 4G E RFID F Bluetooth G CPU system H Isolation I AC DC power supply J AC input K Surge protection L Earth ground fault protection M AC input metering N AC isolation relay O Control pilot P AC output 1 The user initiates a...

Page 14: ...e E RFID card or smartphone F Structure to install the EVSE on G EV charge cable Part Function EVSE Refer to section 2 2 Structure To install the EVSE on and to keep the EVSE in position AC grid input To supply the electricity to the EVSE EV charge cable To conduct the charge from the EVSE to the EV EV The EV of which the batteries need to be charged Parking space Location for the EV during the ch...

Page 15: ...V charge cable Openings Openings for the cables that go into the EVSE LED indicators To show the status of the EVSE and the charge session Refer to section 2 7 1 Cabinet cover To prevent a user to access the installation and mainte nance parts of the EVSE Enclosure To reduce the accessibillity of unqualified persons to the inside of the EVSE RFID reader To authorize the start or stop of a charging...

Page 16: ...nce cover To prevent access to the electrical components of the EVSE Ethernet connection To connect the ethernet cable Socket for a Nano SIM card To connect the EVSE to the internet 3G 4G Smart meter connection To connect the cables for RS485 and ModBus Terminal block for the AC in put To connect the AC input cable from the grid Terminal block for the EV charge cable To connect the EV charge cable...

Page 17: ...ptions 2 6 1 Display A A Display 2 6 2 EV charge cable type 2 2 6 3 Socket type 2 A A Socket The socket for an EV charge cable type 2 is available with or without a shutter Description BCM V3Y01 0 EN 001 17 ...

Page 18: ...tal power demand of the devices that use the grid connection must not exceed the grid capacity The load management feature prevents that the system exceeds the grid capacity and prevents damage of the fuses At times when the current demand is high the Terra AC will pause the charge session The charge session will start again when there is availability on the grid Also the load management feature m...

Page 19: ... authorization LED D Internet connection LED E EVSE on off LED Table 1 Error LED Status of the LED Status of the EVSE On Error Off No error Table 2 Charging LED Status of the LED Status of the EVSE On EV is fully charged or has stopped charg ing Off Not charging Flashing Charging Description BCM V3Y01 0 EN 001 19 ...

Page 20: ...EVSE On Connected to the internet Off Not connected to the internet Flashing The internet connection is set up Table 5 EVSE on off LED Status of the LED Status of the EVSE On The EVSE is on Off The EVSE is off Flashing The EVSE is in setup 2 8 Description of the mobile app for the EVSE 2 8 1 General description of the lay out of the mobile app B A C Xx xxxx xxxx Xxxxx Xxxxxxxxx Xxxxxxxxx Xxxxxxxxx...

Page 21: ...2 8 2 2 8 2 General description of the buttons and colors Button Name color Description Home To go to the main menu Map To go to the map menu Start button To start the charge session Message To go to the message menu Account button To go to the account menu that has the personal preferences and settings Schedule To go to the schedule menu Charger care To go to the charger care menu Energy plan To ...

Page 22: ... of public charge sites Shows the current location of users to help the users to find the nearest available EVSE Message menu To give the user important information Schedule menu To create a schedule for a charge session Charger care menu To show the status of the EVSE in machine life cycle per spective To give solutions for potential problems that can occur during the use of the EVSE Energy plan ...

Page 23: ...l current er ror DC 6mA There is residual current in the charge circuit Current leaks into the ground 0x0104 Residual current er ror AC 30mA There is residual current in the charge circuit Current leaks into the ground 0x0106 Residual current monitor selftest error The residual current monitoring sensor is defec tive 0x0108 Relay stuck error The relay contact is overheated or has damage 0x0110 Cab...

Page 24: ...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 th...

Page 25: ...tions 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 deman...

Page 26: ...with all applicable local rules 3 7 Signs on the EVSE Symbol Risk type General risk Hazardous voltage that gives risk of electrocution Risk of pinching or crushing of body parts Rotating parts cat can cause a risk of entrapment PE Sign that means that you must read the manual before you install the EVSE Waste from electrical and electronic equipment Note It is possible that not all symbols are pre...

Page 27: ...section 6 1 5 Do the electrical installation Refer to section 7 1 6 Install the cabinet cover Refer to section 9 2 7 Do the commissioning procedure Refer to section 8 1 4 2 Unpack the EVSE 1 Open the box 2 Remove the EVSE from the box 3 Remove all packaging material from the EVSE 4 Discard the packaging material Refer to section 3 8 5 Make sure that all parts are delivered according to the order R...

Page 28: ...efer to section 11 10 3 5 2 Prepare the site Preliminary requirements 1 The site must be suitable to install the EVSE Refer to section 5 1 Procedure 1 Make sure that the space and the airflow around the EVSE are sufficient Refer to section 11 10 3 2 Make sure that the correct cables are available at the site AC input cable Refer to section 11 13 ModBus and RS485 cables Refer to section 11 13 4 Eth...

Page 29: ...pper mounting holes B and the lower mounting holes C 3 Remove the installation template 4 Drill the upper and the lower mounting holes 5 Insert the plugs D into the upper mounting holes 6 Insert the plugs E into the lower mounting holes 7 Install the upper mounting screws F Make sure that a part of the screws stays out of the wall For the specifications refer to section 11 8 Note The mounting scre...

Page 30: ...all 1 Put the openings A over the mounting screws B The upper mounting screws support the EVSE 2 Install the mounting screws C For the torque specifications refer to section 11 16 B A C Mechanical installation 30 BCM V3Y01 0 EN 001 ...

Page 31: ...r communication Refer to section 7 4 3 Connect the cables for smart meter communication Refer to section 7 4 4 5 If you want to use the internet insert the Nano SIM card Refer to section 7 4 5 6 If necessary replace the EV charge cable Refer to section 7 5 7 Install the maintenance cover Refer to section 9 4 7 2 Insert the AC input cable Preliminary requirements Screw driver AC input cable Procedu...

Page 32: ...the correct torque For the specification refer to section 11 16 7 3 2 Connect the AC input cable split phase North America Preliminary requirements Torque screw driver AC input cable 1 phase Procedure 1 Loosen the screws A 2 Strip the wires For the specification refer to section 11 13 2 3 Insert the cable connector into the terminal block B 4 Connect the below wires 1 Earthing wire C 2 L2 wire for...

Page 33: ... Earthing wire C 2 Neutral wire D 3 L1 E 4 L2 F 5 L3 G Refer to section 11 11 4 Tighten the screws A to the correct torque For the specification refer to section 11 16 7 3 4 Secure the cables Preliminary requirements Torque screw driver Strain relief for the cable Procedure 1 Secure the cables A with the strain relief B 2 Install the two screws C of the strain relief B E D F G C A A B C Electrical...

Page 34: ...he EVSE 2 Make a hole in the center of the membrane 3 Install the membrane 4 Put the Ethernet cable B through the cable inlet hole 7 4 2 Connect the Ethernet cable Preliminary requirements 1 The Ethernet cable is inserted Refer to section 7 4 1 Procedure 1 Put the RJ45 plug A of the Ethernet cable in the Ethernet RJ45 socket B 2 Connect the Ethernet cable to a PC router or gateway B A A B Electric...

Page 35: ... meter with ModBus RTU interface Wire for RS485 Refer to section 11 13 4 Obey the local rules for the correct wire insulation rating Procedure 1 Remove the plug A of the terminal block B from the terminal block B of the smart meter connection 2 Connect the wires a Connect the positive wire C b Connect the negative wire D c If the smart meter has an earthing wire connect the earthing wire E 3 Tight...

Page 36: ...on 11 13 Torque screw driver Procedure 1 Get access to the EV charge cable connection a Remove the cabinet cover Refer to section 9 1 b Remove the maintenance cover Refer to section 9 3 c Remove the plastic cover 2 Disconnect the EV charger 2 pin connector A that is receptable to the CP PP connector 3 Loosen the screw B on the terminal block output connector C 4 Disconnect the wires L1 D L2 E L3 F...

Page 37: ...fication refer to section 11 16 c Connect the EV charger 2 pin connector that is receptable to the CP PP connector 7 Prepare for operation a Install the plastic cover b Install the maintenance cover Refer to section 9 4 c Install the cabinet cover Refer to section 9 2 Electrical installation BCM V3Y01 0 EN 001 37 ...

Page 38: ... sure that the EVSE works correctly and safely If the EVSE detects a problem the error LED comes on An error code shows on the mobile app Refer to section 2 8 4 for an overview of the error codes 8 3 Set up the EVSE Preliminary requirements Mobile device Procedure 1 Download the mobile app For an Android OS mobile device go to Google Play Store For an iOS mobile device go to Apple Store 2 Open the...

Page 39: ...obile app Procedure 1 Go to the Add Card menu in the mobile app 2 Press Add Card 3 Hold the RFID card against the RFID reader of the EVSE The binding process starts The screen of the mobile app shows the status of the binding process When the binding process is completed the mobile app shows done The My Cards page shows the name or the number of the EVSE in the overview of the added RFID cards 4 M...

Page 40: ...s to parts 9 1 Remove the cabinet cover 1 Remove these parts Screws A Cabinet cover B 9 2 Install the cabinet cover 1 Install these parts Cabinet cover A Screws B B A A B Access to parts 40 BCM V3Y01 0 EN 001 ...

Page 41: ...move the maintenance cover 1 Remove these parts Screws A Maintenance cover B 9 4 Install the maintenance cover 1 Install these parts Maintenance cover A Screws B B A A B Access to parts BCM V3Y01 0 EN 001 41 ...

Page 42: ...The EVSE is over heated The ambient temperature exceeds the operation tem perature specification The EVSE will decrease the current output 1 Do a check of the operation temperature on the type plate 2 If it is necessary install the EVSE in an environment with a lower ambient temperature 3 Do the procedure that is descri bed for the problem the AC in put voltage is too high 4 If you can not solve t...

Page 43: ...ctive If it is necessary replace the RJ45 cable or plug There is no WiFi Do a check of the WiFi signal strength at the site There is no 3G 4G connec tivity 1 Do a check of the Nano SIM card connections 2 Do a check of the 3G 4G signal strength at the site The EV is not charg ed There is a problem with the EVSE 1 Make sure that the power sup ply to the EVSE is on 2 Examine the EVSE to find if is wo...

Page 44: ...ile app or the RFID card 1 Make sure that you have regis tered in the mobile app 2 Make sure that you use a RFID card that the manufacturer pro vided 3 Make sure that the RFID card is added on the mobile app 4 Start the mobile app 5 Start the authorization process 10 3 De energize the EVSE 1 Open the breaker that supplies the power to the EVSE 2 Wait for minimum 1 minute Troubleshooting 44 BCM V3Y...

Page 45: ...ype or socket P Type 1 cable G Type 2 cable T Type 2 socket S Type 2 socket with shutter A5 Cable length No cable 5 5 m 8 8 m A6 Authorization R RFID enabled No RFID A7 Ethernet Single D Double A8 Metering M Certified only with display Not certified A9 SIM slot C Yes No A10 Display D Yes No Example Terra AC W22 SR 0 A1 Brand name Terra AC A2 Type Wallbox A3 22 Power output 22 kW A4 Cable type sock...

Page 46: ...ed upstream protection device s Options RCD Type A minimum MCB RCBO Type A minimum for exam ple ABB model PN DS201 C40 A30 Upstream overcurrent protection breaker for example RCBO or MCB Note The breaker value de pends on the diameter and the length of the cable the EVSE rating and the environmental parameters for the electrician to decide The breaker serves as the main disconnect switch to the EV...

Page 47: ...Parts included in the delivery Parameter Specification EVSE Refer to the type plate Refer to section 2 3 Upper mounting screws M6 x 60 Plugs for the upper mounting screws servi cable for a brick wall 8 x 60 mm Lower mounting screws M6 x 120 Plugs for the lower mounting screws servi cable for a brick wall 10 x 60 mm Installation template RFID card MIFARE 11 5 General specifications Parameter Specif...

Page 48: ...lation Parameter Specifications Hammer Spirit level Drill Torque screw driver cross Torque screw driver slotted For terminal blocks and plugs with 5 mm pitch 11 7 Ambient conditions Parameter Value Operation temperature 35 C to 50 C Storage temperature 40 C to 80 C Storage conditions Indoor dry Relative humidity 95 non condensing 11 8 Requirements for the wall Parameter Value Wall thickness Minimu...

Page 49: ... Noise level Parameter Specification Noise level Maximum 70 dB A 11 10 Dimensions 11 10 1 AC input with socket cable Type 2 Z1 Y2 Y1 X Z2 X Width of the EVSE Y1 Depth of the EVSE Y2 Depth of the socket Z1 Height of the EVSE Z2 Distance from the bottom of the EVSE to the center of the socket Parameter Value mm X 195 Y1 110 Y2 33 Z1 320 Z2 70 Technical data BCM V3Y01 0 EN 001 49 ...

Page 50: ...ith EV charge cable Z Y X X Width of the EVSE Y Depth of the EVSE Z Height of the EVSE Parameter Value mm X 195 Y 110 Z 320 11 10 3 Space requirements for installation Z2 Z1 A A EVSE Technical data 50 BCM V3Y01 0 EN 001 ...

Page 51: ...ystems TT TN S TN C S IT Frequency 50 Hz or 60 Hz Overvoltage category Category III Protection Overcurrent Overvoltage Undervoltage Earth fault including DC leakage protection Integrated surge protection 11 11 2 400 VAC 3 phase with neutral TT TN Europe Phase A PE Neutral N Phase B Phase C L1 N L2 L3 U1 U2 U1 230 VAC maximum 264 VAC U2 400 VAC maximum 460 VAC Technical data BCM V3Y01 0 EN 001 51 ...

Page 52: ...C L1 L3 L2 U1 U2 U1 230 VAC maximum 264 VAC U2 230 VAC maximum 264 VAC 11 11 4 230 VAC 1 phase Europe Phase A PE Neutral N L1 N U1 U1 230 VAC maximum 264 VAC 11 11 5 120 VAC North America Phase A PE Neutral N L1 N U1 U1 120 VAC maximum 264 VAC Technical data 52 BCM V3Y01 0 EN 001 ...

Page 53: ...ications North America Parameter Specification Input AC power connection 1 phase or split phase 110 to 240 V AC Standby power consumption 4 W Earth ground fault protection internal 20 mA AC CCID 11 12 General logic interface specifications Parameter Specification Connectivity Mobile communication with Nano SIM socket Europe GSM 4G LTE WCDMA North America 4G LTE WCDMA Smart meter communication Modb...

Page 54: ...Diameter of the phase conductors Refer to the local rules Diameter of the PE conductor The same as te diameter of the phase con ductors Consult your local electrical codes for the correct wire size based on the environ ment the conductor type and the rating of the EVSE The wire cross sectional area is based on the copper wire type 11 13 2 AC input cable North America Parameter Specification EV cha...

Page 55: ... block plug allowed Europe IEC cross sectional area 2 5 mm2 to 0 5 mm2 North America UL 12 AWG to 30 AWG Conductor size for the terminal block plug recommended Minimum 24 AWG 0 5 mm2 Strip length 5 mm Terminal connections 485A RS485 Positive A D0 485B RS485 Negative B D1 PE Common isolated ground for shielded cable optional ModBus RTU baud rate 300 to 19 2K bps ModBus RTU bus master Terra EV charg...

Page 56: ...l lowed maximum 2 5 0 5 mm2 Europe 12 30 AWG North America Wire size for the terminal block plug rec ommended 20 AWG 0 75 mm2 minimum Required torque 0 5 Nm Strip length 5 mm Terminal connections Configuration output dry contact 1 Contact output terminal 1 Configuration output dry contact 2 Contact output terminal 2 Contact rated load 125 VAC 30VDC at 3A The wire AWG and cross section are based on...

Page 57: ...nection standard Type 1 cable according to SAE J1772 Maximum output voltage 19 kW 11 15 Specific power consumption specifications Power consumption during normal opera tion Specification W Charging Mode 1 Phase 7 Charging Mode 3 Phase 10 11 16 Torque specifications Parameter Specification Nm lb in Terminal block for the AC input 1 2 10 6 Terminal block for the communication wires and the smart met...

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