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ABB HVC 200 User Manual

ABB HVC 200
92 pages
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Operation and installation manual
HVC 200-300-360 UL
©
Copyright ABB. All rights reserved

Table of Contents

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ABB HVC 200 Specifications

General IconGeneral
BrandABB
ModelHVC 200
CategoryIndustrial Equipment
LanguageEnglish

Summary

About this document

Function of this document

Explains the document's purpose and scope for EVSE operation.

Target group

Identifies intended users like owners and installation engineers.

Revision history

Lists document versions, dates, and changes.

Language

States the original language and translation notes.

Illustrations

Notes that illustrations show typical setups for instruction.

Units of measurement

Specifies SI and North American units used in the manual.

Typographical conventions

Explains formatting for lists and procedures.

How to use this document

Provides guidance on navigating and understanding the manual.

General symbols and signal words

Defines common symbols and signal words for safety and information.

Special symbols for warnings and dangers

Details specific symbols indicating risks like voltage, pinching, heat.

Manufacturer and contact data

Provides contact information for ABB E-mobility support.

Abbreviations

Lists and defines common abbreviations used in the manual.

Terminology

Defines key terms and concepts related to the EVSE.

Orientation agreements

Explains coordinate system (X, Y, Z) for EVSE orientation.

Safety

Liability

Outlines manufacturer's non-liability for damages due to non-compliance.

General safety instructions

Mandates following procedures, using qualified personnel, and obeying laws.

Responsibilities for the owner

Details owner's duties regarding safety, laws, and site conditions.

Required qualifications for the qualified installation engineer

Specifies engineer's knowledge, qualifications, and adherence to rules.

Personal protective equipment

Lists required PPE like clothing, gloves, shoes, and glasses.

Safety instructions during transport

Covers safe handling during transport, including hoisting and forklift use.

Safety instructions during installation

Emphasizes safe practices during the physical installation process.

Safety instructions for use

Warns against using damaged or unsafe EVSEs and conditions.

Safety instructions during cleaning or maintenance

Advises on safety measures for cleaning and maintenance tasks.

Safety instructions for earthing

Details proper grounding procedures and compliance with local rules.

Signs on the EVSE

Explains various hazard and information symbols found on the EVSE.

Discard the EVSE or parts of the EVSE

Guides on environmentally sound disposal and recycling of EVSE components.

Cyber security

Addresses security responsibilities for network connections and data protection.

FCC compliance statement

Provides information on FCC regulations and compliance for the device.

Description

Type plate

Details the information displayed on the EVSE's type plate.

Intended use

Specifies the EVSE's intended application and restrictions.

System overview

Provides a high-level diagram of the EVSE system components.

Power cabinet, outside

Describes the external components and features of the power cabinet.

Power cabinet, inside

Details the internal components and their functions within the power cabinet.

AC plate

Explains the components and connections on the AC power plate.

DC plate

Describes the components and connections on the DC power plate.

Cable glands in the power cabinet

Illustrates cable entry points and gland types in the power cabinet.

Control elements

Covers the user interface elements, including LED indicators.

LED indicators

Explains the meaning of different LED colors and patterns for EVSE status.

Power allocation strategies

Discusses how power is distributed among multiple EVSE outlets.

Static allocation

Describes fixed power distribution based on outlet availability.

Dynamic allocation

Mentions dynamic power sharing, currently unavailable.

Options

Lists optional features available for the EVSE.

Emergency stop button (EMO)

Details the function and installation of the optional emergency stop button.

Transport, handling and unpacking

Transport the EVSE to the site

Covers delivery responsibilities and storage conditions for the EVSE.

Hoist the packaged cabinet

Provides instructions for safely lifting the packaged EVSE.

Move the packaged cabinet with a forklift truck

Details procedures for moving the EVSE using a forklift.

Unpacking

Covers the steps for safely removing the EVSE from its packaging.

Unpacking procedure

Outlines the process for unpacking and checking delivered parts.

Do a check of the transport sensors

Explains how to check sensors for shocks or tilt during transport.

Pre-installation

Prepare the site

Covers site preparation, space, airflow, and cable routing requirements.

Control the space and airflow around the EVSE

Ensures adequate clearance and unobstructed airflow for the EVSE.

Install the cable ducts

Describes the installation of cable ducts for routing and protection.

Prepare the foundation

Details requirements for preparing a suitable foundation for the EVSE.

Prepare a foundation - general procedure

General steps for preparing foundations based on surface type.

Prepare the foundation for the power cabinet (concrete)

Specific instructions for preparing a concrete foundation.

Prepare a metal foundation for the power cabinet

Instructions for preparing a metal frame foundation.

Install the cable gland plate for the concrete foundation of the power cabinet

Guides on installing the cable gland plate onto a concrete foundation.

Installation

Install the power cabinet - general procedure

Overview of the steps for installing the power cabinet.

Mechanical installation

Covers physical mounting and securing of the power cabinet.

Mechanical installation of the power cabinet - general procedure

General steps for the mechanical installation of the cabinet.

Install the cabinet on the foundation

Details securing the cabinet to the prepared foundation.

Install the cover plates of the metal foundation

Instructions for installing cover plates on a metal foundation.

Electrical installation

Covers all wiring and electrical connections for the EVSE.

Electrical installation of the power cabinet - general procedure

Overview of the electrical connection steps for the cabinet.

Connect the PE wire of the AC input cable

Step-by-step guide for connecting the protective earth wire.

Connect the AC input wires

Instructions for connecting the main AC power input wires.

Connect the AC auxiliary power cable (3 phase 480 V) in the power cabinet

Details connecting the 3-phase 480V auxiliary power cable.

Connect the AC auxiliary power cable (1 phase 120 V) in the power cabinet

Details connecting the 1-phase 120V auxiliary power cable.

Connect the DC power cables

Instructions for connecting the main DC power cables to outlets.

Connect the DC auxiliary power cables (24 V) to the power cabinet

Guides on connecting 24V DC auxiliary power cables.

Connect the interlock and DC guard cables to the power cabinet

Details connecting safety interlock and DC guard signal cables.

Connect the Ethernet output cables to the power cabinet

Instructions for connecting Ethernet communication cables.

Connect the optical fiber cables (Ethernet to fiber)

Guides on connecting Ethernet to fiber optic converters.

Connect the optical fiber cables (CAN to fiber)

Guides on connecting CAN bus to fiber optic converters.

Installation procedure for the the long distance kit (optional)

Steps for installing the optional long-distance communication kit.

Disconnect the ethernet cable from the converter

Procedure for safely disconnecting an Ethernet cable from a converter.

Connect the ethernet cable to the connector

Steps for connecting an Ethernet cable to its designated connector.

Connect the EMO cable to the power cabinet (optional)

Details connecting the optional Emergency Stop (EMO) cable.

Install a ferrule on a wire

Explains the process of crimping ferrules onto wire ends.

Connect a wire that has a ferrule

Details connecting wires that have already been fitted with ferrules.

Precommissioning mode

Covers the initial setup and configuration phase before full commissioning.

General information

Provides background on precommissioning mode and its requirements.

Precommissioning mode - general procedure

Outlines the overall steps for entering and using precommissioning mode.

Do an inspection of the PE connection

Describes checking the integrity of the protective earth connection.

Connect the 120 V cable for the precommissioning mode

Details connecting the 120V AC supply for precommissioning.

Do a check on the electrical parts

Verifies the condition and position of electrical components.

Set the precommissioning switch

Instructions for setting the precommissioning mode switch.

Commissioning

Precommissioning mode

Steps to confirm the EVSE is ready for commissioning.

Do a check on the status of the precommisioning mode

Verifies correct settings and connections before commissioning.

General procedure

Outlines the general steps to exit precommissioning mode.

Set the precommissioning switch

Details setting the switch to the correct position for commissioning.

Remove the 120 V cable for the precommissioning mode

Describes disconnecting the temporary 120V supply.

Prepare for commissioning

Final checks and requirements before the official commissioning process.

Operation

Prepare before use

Steps for final checks and appointing personnel before operation.

Emergency stop

Explains how to use the emergency stop button to halt operations.

Reset the EVSE after an emergency stop

Procedures for safely resetting the EVSE after an emergency stop.

Charge session

Covers the process of charging an electric vehicle.

Charge an EV

Basic steps for initiating and managing an EV charging session.

Start a charge session

Details how to begin the EV charging process.

Stop a charge session

Instructions for ending a charging session.

Maintenance and cleaning

Maintenance schedule

Outlines the recommended tasks and frequencies for EVSE maintenance.

Do a check on the cabinet

Guides on inspecting the power cabinet for damage or wear.

Clean the EVSE

Provides instructions for safely cleaning the EVSE unit.

Access to parts

Open the door of the power cabinet

Step-by-step instructions for opening the main power cabinet door.

Close the door of the power cabinet

Details how to securely close the main power cabinet door.

Remove the plinth covers of the power cabinet

Explains how to remove the covers at the base of the power cabinet.

Install the covers

Instructions for installing various protective covers onto the cabinet.

Remove the AC cover

Procedures for removing the cover protecting AC components.

Install the AC cover

Steps for reinstalling the AC component cover.

Open the DC door

Instructions for opening the door providing access to DC components.

Close the DC door

Details how to securely close the DC component access door.

Troubleshooting

Troubleshooting procedure

Guides on diagnosing and resolving issues with the EVSE.

Technical data

Types of EVSE

Classifies different EVSE models based on power, outlets, and variants.

EVSE type

Explains the coding system for identifying EVSE models.

HVC variants

Lists specific ABB part codes and short descriptions for HVC models.

Parts included in the delivery

Lists the components provided with the EVSE.

Required parts for installation

Specifies additional parts needed for installation, like fasteners.

Torque specifications

Provides torque values for various fasteners and connections.

General specifications

Lists overall compliance, IP rating, and EMC specifications.

Cleaning specifications

Defines appropriate cleaning agents and tools for the EVSE.

Dimensions and mass

Provides physical dimensions and weight of the EVSE.

Cable slack

Specifies the required slack for various cables.

Space requirements

Details the necessary clearances around the EVSE for installation and operation.

Foundation specifications

Outlines requirements for the foundation supporting the EVSE.

Power cabinet (custom foundation)

Provides detailed dimensions for custom concrete foundations.

Power cabinet (metal frame)

Specifies dimensions for metal frame foundations.

Ambient conditions

Lists acceptable operating and storage temperature and humidity ranges.

Wiring diagram for the optical fiber cables

Illustrates connections for optical fiber communication cables.

Cable specifications

Details various types of cables used with the EVSE.

General specifications for cables

General requirements for cable compliance and resistance.

AC input cables

Specifies parameters for the main AC input cables.

AC auxiliary power cable (3 phase 480 V AC)

Details specifications for 3-phase 480V auxiliary power cables.

AC auxiliary power cable (1 phase 120 V)

Details specifications for 1-phase 120V auxiliary power cables.

DC power cables

Specifies parameters for the main DC power cables.

DC auxiliary power cables

Details specifications for 24V DC auxiliary power cables.

PE cables

Specifies parameters for protective earth cables.

Interlock cables

Details specifications for interlock signal cables.

Interlock + DC guard cable

Specifies parameters for combined interlock and DC guard cables.

Ethernet cables

Details specifications for Ethernet communication cables.

Optical fiber cables

Specifies parameters for optical fiber communication cables.

AC input specifications

Provides electrical input data for different power configurations.

200 kW configuration

Electrical input specifications for the 200 kW EVSE model.

300 kW configuration

Electrical input specifications for the 300 kW EVSE model.

360 kW configuration

Electrical input specifications for the 360 kW EVSE model.

DC output specifications

Details the DC power output capabilities of the EVSE.

DC output specifications

Lists maximum output voltage and current ratings.

Power curve

Shows voltage-current curves for different EVSE power outputs.

Protection for the AC auxiliary

Specifies circuit breaker ratings for AC auxiliary circuits.

Power consumption specifications

Provides standby power consumption details.

Terminal part numbers

Lists part numbers and colors for various terminal blocks.

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