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ABB HVC-PD Installation Manual
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ABB HVC-PD Installation Manual

ABB HVC-PD Installation Manual

Depot e-bus charger
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IN STA LL AT I ON G U ID E
HVC-PD Depot E-Bus Charger
Installation Guide for EU products
Version 1.3

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Summary of Contents for ABB HVC-PD

  • Page 1 — IN STA LL AT I ON G U ID E HVC-PD Depot E-Bus Charger Installation Guide for EU products Version 1.3...
  • Page 2 ABB cannot be held liable for errors in the translation. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents there of must not be imparted to a third party nor used for any unauthorized purpose.
  • Page 3 HVC-PD Depot E-Bus Charger Installation Guide Version control Version Date Remarks 07-06-2019 Released for review. 26-08-2019 Commercial release. 07-07-2020 Add description to connect DC- OVP Sensing wire in ACM. Changes made according to Mantis issue 12192. Distance sensor is removed form Charge Pole.
  • Page 4 1.6. Cyber Security Disclaimer 1.7. Contact information Description of the product 2.1. Overview of the system 2.1.1. Standard HVC-PD 150 kW E-Bus Charger system 2.1.2. Standard HVC-PD 300 kW E-Bus Charger system 2.1.3. Standard HVC-PD 450 kW E-Bus Charger system 2.1.4.
  • Page 5 HVC-PD Depot E-Bus Charger Installation Guide 3.10. Lightning protection Construction 4.1. Construct foundation of the Power Cabinet 4.1.1. Options 4.1.2. Workflow with concrete foundation 4.1.3. Workflow with metal frame foundation 4.1.4. Workflow mounting Power Cabinet direct on a floor (footprint) 4.2.
  • Page 6 HVC-PD Depot E-Bus Charger Installation Guide 5.8. Connect AC utility power, Interlock and CAN cables Power Cabinet 5.8.1. Route the cables to the terminal blocks 5.8.2. Connect the AC utility power cable 5.8.3. Connect the Interlock cable for the HVC 150 kW system 5.8.4.
  • Page 7 HVC-PD Depot E-Bus Charger Installation Guide Service and Maintenance 7.1. About Service and Maintenance 7.2. Cleaning of the cabinet Technical Specification 8.1. Electrical specification complete 150 kW system 8.2. Electrical specification complete 300 kW system 8.3. Electrical specification complete 450 kW system 8.4.
  • Page 8 HVC-PD Depot E-Bus Charger Installation Guide Glossary OPP Charge Alternating Current. Is a trade name of fast charging method for electric vehicles. ACS Control Module Owner The legal owner of the charger. Automatic Control System. In this charger Pantograph system the pantograph.
  • Page 9 This guide describes the physical installation of the HVC-PD Depot E-Bus Charger at its location. The HVC-PD Depot E-Bus Charger is a DC fast charger system for hybrid or electrical buses that can be used within bus depots which is based on the CCS Charging standard. It is not permitted to use the HVC-PD Depot E-Bus Charger to charge any other equipment, or to use the HVC-PD Depot E-Bus Charger for any other purposes.
  • Page 10 HVC-PD Depot E-Bus Charger Installation Guide WARNING Pinch Hazard Identifies a hazard that could result in injuries in which some body parts are pinched or crushed. WARNING Fall Hazard Identifies a hazard that could result in injury due unsafe work at height.
  • Page 11 ABB’s warranty policy. • Neither ABB nor its affiliates shall be liable to the purchaser of this product or third parties for damages, losses, costs or expenses incurred by purchaser or third parties...
  • Page 12 Instruct and warn people about the potential harmful high voltages. 5. The installation and maintenance personnel must supply their own lighting equipment, since the HVC-PD E-Bus Charger has no lights inside the cabinet. 6. Always connect the Protective Earth (PE) first, before connecting the neutral (N) and Phase (P) wiring.
  • Page 13 ABB Ltd and its affiliates are 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.
  • Page 14 HVC-PD Depot E-Bus Charger Installation Guide 1.7. Contact information ABB in your country Please contact ABB in your country for delivery and service information. ABB EV Infrastructure global ABB EV Infrastructure Address Heertjeslaan 6 2629 JG Delft The Netherlands Telephone...
  • Page 15 ABB offers a standard delivery system configurations with a DC charge power of 150, 300 or 450 kW. Additional needed components can be ordered separately and are not part of the standard delivery.
  • Page 16 1x Junction Box NOTICE The cables between the Power Cabinet(s) and HVC-PD kit ACM 150- 450kW is not part of the order. See section Cabling on Page 47 for selecting the right cable type needed between the Power Cabinet(s) and Charge kit.
  • Page 17 HVC-PD Depot E-Bus Charger Installation Guide Inside view of the HVC 150 Power Cabinet Main switch Display AC Power connection Power Modules Guidance plate of the cables Data/communication connection 2.1.5. ACS Control Module Outside view of the ACS Control Module...
  • Page 18 HVC-PD Depot E-Bus Charger Installation Guide Inside view of the ACS Control Module Communication connection Connection block Protection cover for DC contactors 2.1.6. Junction Box Outside view Junction Box Cover In- and outputs DC power cables Output DC- OVP sensing cable (cable is included, length is 750 mm) Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020...
  • Page 19 Tension spring Collector head 2.2. Accessories The following parts can be ordered at the time of the initial order or afterwards. Contact ABB Sales department (see Contact information on Page 14 for contact details). 2.2.1. Foundation for Power Cabinet Concrete foundation The concrete foundation can be used to install the Power Cabinet on soil.
  • Page 20 HVC-PD Depot E-Bus Charger Installation Guide Metal frame foundation The metal frame foundation can be used to install the Power Cabinet on a solid surface. Foundation Front border cover Rear border cover Amount Part number Description 4EPY420133R1 HxC power cabinet metal foundation 2.2.2.
  • Page 21 HVC-PD Depot E-Bus Charger Installation Guide 2.2.4. Communication glass fiber cable The CAN and Ethernet communication between the Power Cabinet and Charge control set is done via a glass fiber cable. This glass fiber cable must be prefabricated and can be ordered separately.
  • Page 22 Beacon displays the status of the charging system. Amount Part number Description 1SFA616070R3051 Red permanent light element with integrated LED, KL70-305R (ABB) 1SFA616070R3052 Green permanent light element with integrated LED, KL70-305G (ABB) 1SFA616070R3054 Blue permanent light element with integrated LED, KL70-305L (ABB) There are different possibilities to mount the beacon.
  • Page 23 KA70-1033 1SFA616077R1033 For surface mounting KA70-1034 1SFA616077R1034 2.2.7. WiFi antenna The WiFi antenna is an essential part of the HVC-PD E-Bus Charger system. This takes care of the communication between the charger and the bus. Amount Part number Description 1356.17.0008...
  • Page 24 HVC-PD Depot E-Bus Charger Installation Guide The RFID unit is available for the following regions: 00 = Europe / Saudi Arabia / South Africa 01 = USA / Canada / Mexico 02 = Australia 03 = India 04 = Brazil...
  • Page 25 The different phases of the full project plan are shown in the figure below: A. Preparation The owner / site operator has ordered a HVC-PD Depot E-Bus Charger. In this phase all preparation work must be done before the contractor can do the civil and electrical works.
  • Page 26 • Wireless, which requires coverage to a 3G network at the location. This is the preferred connection. A 3G modem with active SIM card is included with the HVC-PD Depot E- Bus Charger (a customer SIM card is not required).
  • Page 27 Otherwise the temperature inside the cabinet might exceed the maximum temperature. • Do not install or use the HVC-PD Depot E-Bus Charger in areas where there is an explosion hazard. You must provide information about the HVC-PD Depot E-Bus Charger to the fire brigade.
  • Page 28 • Maximum allowed pressure drop = 300 pA. If the pressure drop of the room is higher than 300 pA an extra fan should be placed. Contact ABB Sales department (see Contact information on Page 14 for contact details). 3.5.2. Placement of multiple cabinets There two possible configurations for the placement of multiple HVC 150 systems, see picture below.
  • Page 29 HVC-PD Depot E-Bus Charger Installation Guide 3.5.3. Required space for the ACS Control Module/Junction Box The ACS Control Module and Junction Box must be mounted on a wall. The following requirements must be taken into account when determining the location of the ACS Control Modules and the Junction Box: •...
  • Page 30 (TOR) is flat (no wear); ➢ Compensation of angles: X-axis ≤ 3.5⁰, Z-axis ≤ 2.5⁰. NOTICE ABB can help with the calculation of the position of the Pantograph. Contact ABB Sales department (see Contact information on Page 14 for contact details).
  • Page 31 HVC-PD Depot E-Bus Charger Installation Guide 3.6.3. Maximum allowed slope of the pantograph in Z-axis The maximum inclination of the pantograph in Z-axis is 2.5°. This allows to compensate a slope of the floor space of the bus (road gradient), see section Pivoting of the collector head around the pantograph axis (Z-axis) on Page 30.
  • Page 32 HVC-PD Depot E-Bus Charger Installation Guide The working area in which the pantograph has a the right force to make contact force with the contact rails is 1150 mm; the upper working position is 850 mm and the lower working position is 2000 mm measured from the mounting point of the pantograph (see picture above).
  • Page 33 HVC-PD Depot E-Bus Charger Installation Guide The picture below shows the curve the collector head of the pantograph make when lowering down. The -474 mm is the start position of the collector head measured from the mounting point of the pantograph. This S-curve must be taken into account when determining the correct position of the pantograph in the Y-Axis.
  • Page 34 HVC-PD Depot E-Bus Charger Installation Guide Due to the S-curve of the pantograph offsets result for the working area in Y-Axis of -75mm to +84mm. Due to the S-curve the height of the bus has to be taken into account when positioning the pantograph above the road so that the vehicle can be positioned at the low accuracy of ±...
  • Page 35 HVC-PD Depot E-Bus Charger Installation Guide In this case the pantograph’s collector head make the right electrical contact with the contact rails on the roof of the bus, see picture below. 3.6.6. Maximum slope of the road in X-axis The maximum slope of the road sideways direction is 3.5⁰, including the kneeling of the bus.
  • Page 36 HVC-PD Depot E-Bus Charger Installation Guide 3.7. WiFi antenna position in relation to the bus The WiFi antenna is an essential part of the HVC-PD E-Bus Charger system. This takes care of the communication between the charger and the bus. To establish good communication, the WiFi antenna must be located above the WiFi receiver/transmitter on the bus during the charge session.
  • Page 37 The activities of installing cable conduits (for underground), ducts or trays for the supply of cables between the different parts of the HVC-PD Depot E-Bus Charger, are entirely dependent of the location, and may differ per location. Due to this reason, the installation of those cable conduits, ducts or trays our out of the scope of this Installation Guide.
  • Page 38 Power Cabinet and the ACS Control Module are placed in to the ground. Depending on the location, for example the HVC-PD Depot E-Bus Charger is installed inside, the cables can installed above the ground. In this case there is needed cable ducts or trays to protect the cables. Check with your local contractor what the installation options are, because this is not described in this Installation Guide.
  • Page 39 HVC-PD Depot E-Bus Charger Installation Guide Foundation of Power Cabinet Wall on which the ACS Control Module and Junction Box will be mounted Flexible conduit for DC power cables Flexible conduit for AC auxiliary power, PE wire and data cables...
  • Page 40 HVC-PD Depot E-Bus Charger Installation Guide 4. Construction The construction phase includes all work required to prepare the location and make it ready for the placement and connection of the HVC-PD Depot E-Bus Charger. The construction phase can start when: •...
  • Page 41 HVC-PD Depot E-Bus Charger Installation Guide 4.1.2. Workflow with concrete foundation WARNING Make sure that personnel cannot be crushed or become trapped while moving the foundation. Be aware that the weight of the concrete foundation is about 1300 kg. CAUTION Before you lower the foundation, remove sharp edges of the cable holes (B) in the foundation to protect the cables.
  • Page 42 HVC-PD Depot E-Bus Charger Installation Guide NOTICE This extra cable length is required to connect the AC power cable with the connectors in the Power Cabinet without problems. 11. Place both cover plates on the appropriate place on the foundation.
  • Page 43 HVC-PD Depot E-Bus Charger Installation Guide 4.1.3. Workflow with metal frame foundation Place the frame (A) in the desired position and mark the position of the holes for drilling. NOTICE The hole distance of 655mm on either side of the metal frame foundation is not equal to the hole distance (680 mm) from the HVC 150(S) cabinet.
  • Page 44 HVC-PD Depot E-Bus Charger Installation Guide 4.1.4. Workflow mounting Power Cabinet direct on a floor (footprint) Drill and tap holes in the floor at the indicated positions (A). The holes must be suitable for bolt size M16. Make rectangular holes on the indicated positions (B) and (C). For detail drawings bottom view of Power Cabinet see Appendix A Dimensions Power Cabinet.
  • Page 45 HVC-PD Depot E-Bus Charger Installation Guide 4.2. Mounting preparation of the ACS Control Module 4.2.1. Options There is one option to install the ACS Control Module: • Wall mounting The ACS Control Module can be mounted on a solid wall.
  • Page 46 HVC-PD Depot E-Bus Charger Installation Guide Drill holes in the wall at the indicated positions (A) of one of the chosen mounting options (see pictures above). For a concrete or stony wall, the holes must be suitable for a wall plug with a diameter of 10 mm.
  • Page 47 It is the responsibility of the contractor to setup a routing plan for the cable ducts, and installing this cable ducts on location. 4.4. Cabling 4.4.1. Charge system configurations Overview electrical connections of a HVC-PD 150 kW charge system Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 47 of 145...
  • Page 48 HVC-PD Depot E-Bus Charger Installation Guide Overview electrical connections of a HVC-PD 300 kW charge system 4.4.2. Overview electrical connections of a HVC-PD 450 kW charge system Separated electrical diagrams for the different HVC-PD Charge systems are available: • 6AGA000008-0614, Electrical diagram HVC-PD 150 kW Depot E-Bus Charger, Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020...
  • Page 49 6AGA000008-0615, Electrical diagram HVC-PD 300 kW Depot E-Bus Charger, • 6AGA000008-0616, Electrical diagram HVC-PD 450 kW Depot E-Bus Charger. Contact ABB Sales department (see Contact information on Page 14 for contact details) to request the electrical diagrams. 4.4.3. AC power cable For Power Cabinet: •...
  • Page 50 Pantograph is 20 m. Take this into account when physically placing the ACS Control Module in relation to the pantograph. The following cables are not in the scope of supply of ABB. • 2x, 4x or 6x DC power cables (depending on system configuration), •...
  • Page 51 HVC-PD Depot E-Bus Charger Installation Guide 4.4.9. Cable specification list Tables below provides general specifications for the needed cables. Use these tables to select cables, taking into account local installation conditions, cable length, cable temperature rating, losses and local regulations.
  • Page 52 HVC-PD Depot E-Bus Charger Installation Guide Data cables Functional description Interlock cable CAN cable WiFi cable Number of (twisted) pairs 2 x 2 1 x 2 1 x Coaxial 0.75 – 2.5 mm 0.5 – 0.75 mm Cross section Min – Max external 13 –...
  • Page 53 In most cases the integrated 3G modem is used for wireless internet access. A customer SIM card is not required. If there is no 3G signal available, a standard wired internet connection is required. For this option, contact ABB Sales department (see Contact information on Page 14 for contact details).
  • Page 54 HVC-PD Depot E-Bus Charger Installation Guide 5. Placement and Connection 5.1. About placement and connection When the construction phase is finished, the HVC-PD Depot E-Bus Charger can be installed and connected. 5.2. Route the cables Unpack the cables. See Cabling on Page 46 for details which cables must be used.
  • Page 55 HVC-PD Depot E-Bus Charger Installation Guide For the DC power cables, make sure that a cable length of 1000 mm is available above the surface for internal routing in the cabinet. For the other cables, make sure that a cable length of 3000 mm is available above the surface for internal routing in the cabinet.
  • Page 56 HVC-PD Depot E-Bus Charger Installation Guide 5.3.2. Remove packaging Preconditions • Tools: spanner (size 24). Remove the packaging material from the Power Cabinet. Remove the bag which contain the keys, cover caps and mounting material that are attached with tape on one of the lifting eyebolt at the top of the cabinet.
  • Page 57 HVC-PD Depot E-Bus Charger Installation Guide DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position. Do a voltage check to make sure that the electrical power is disconnected from the system. Secure against resetting.
  • Page 58 HVC-PD Depot E-Bus Charger Installation Guide Insert the bolts (A) or (B) into the holes at the opposite corners of the cabinet, if not placed upon delivery. Tighten the bolts. Connect the hoisting equipment (C). CAUTION Keep the hoisting angle below 60⁰.
  • Page 59 HVC-PD Depot E-Bus Charger Installation Guide 5.5. Install Power Cabinet onto the foundation 5.5.1. Connect Power Cabinet to foundation Preconditions: • Tools: spanner (size 24). • Cover caps (4x) that were removed from the Power Cabinet (bag with parts). •...
  • Page 60 HVC-PD Depot E-Bus Charger Installation Guide Placement on metal frame foundation Foundation Power Cabinet Cables Tapped holes Carefully lower the Power Cabinet (B) onto the foundation (A). Make sure that you do not trap the cables (C). Make sure that the cabinet is aligned with the tapped holes (D).
  • Page 61 HVC-PD Depot E-Bus Charger Installation Guide Tighten the bolts. Remove the swivel eye bolts or lifting loops (A). Place the cover caps (B) in the holes (4x). 5.5.2. Open the door of the Power Cabinet Preconditions: • Key that were removed from the Power Cabinet (bag with parts).
  • Page 62 HVC-PD Depot E-Bus Charger Installation Guide 5.5.3. Move the sliding plate of the guidance plates of the cabinet Preconditions: • Tools: spanner (size 13). Loosen the bolts (A). Move the sliding plate (B) of the 2 guidance plates. 5.5.4. Route cables through guidance plates Route the cables (A) through the right guidance plates (B).
  • Page 63 HVC-PD Depot E-Bus Charger Installation Guide NOTICE A length of 3000 mm is required, because the connection of the cables with the connectors in the Power Cabinet is at the middle of the cabinet. 5.5.5. Move sliding plates of the guidance plates of the cabinet Preconditions: •...
  • Page 64 HVC-PD Depot E-Bus Charger Installation Guide 5.5.6. Install border covers of the Power Cabinet Preconditions: • Tools: torx screwdriver (size 2163TX-T30). • M5 bolts (8x) that were removed from the Power Cabinet (bag with parts). Put the front cover (A) against the bottom front of the Power Cabinet by aligning the four bolts at the back side of the front cover (A) with the holes in the bottom front.
  • Page 65 HVC-PD Depot E-Bus Charger Installation Guide Put the front border cover (A) against the bottom front of the Power Cabinet. Put the rear border cover (B) against the rear front of the Power Cabinet. Insert the M5 bolts (C) into the holes (8x).
  • Page 66 HVC-PD Depot E-Bus Charger Installation Guide Insert the M12 bolts (C) into the holes (4x). Tighten the bolts. 5.6. Connect AC power cable and PE wires Power Cabinets 5.6.1. Remove the protection covers Preconditions: • Tools: cross-head screwdriver Remove the protection plate (A) by loosening the screws (B).
  • Page 67 HVC-PD Depot E-Bus Charger Installation Guide 5.6.2. Connect the PE wire of the AC power cable Preconditions: • Parts (per cabinet): tubular cable lug (1x). • Tools: wire cutter, wire stripper, crimp pliers, spanner (size 19), torque wrench (size 19).
  • Page 68 HVC-PD Depot E-Bus Charger Installation Guide 5.6.3. Connect the AC power cable Preconditions: • Parts (per cabinet): tubular cable lug (3x). • Tools: wire cutter, wire stripper, crimp pliers, spanner (size 19), torque wrench (size 19). DANGER Make sure that the main switch of the power supply group for the product is set to the OFF position.
  • Page 69 HVC-PD Depot E-Bus Charger Installation Guide 5.6.4. Install the protection covers Preconditions: • Tools: cross-head screwdriver Take the 3 protection covers that was removed in Remove the protection covers on Page Place the protection covers (D) back on the connector blocks (C).
  • Page 70 Leave the main switch switched off. The Power Cabinet is not ready for use yet. If there is no appointment for commissioning yet, contact the ABB Delivery department to make an appointment for commissioning. See Error! Reference source not found. on Page Error! Bookmark not defined.
  • Page 71 HVC-PD Depot E-Bus Charger Installation Guide 5.6.6. Connect the PE wire to the Charge Pole NOTICE The PE wire to the Charge Pole is only connected within the HVC 150 Power Cabinet, see for more details section Cabling on Page 46.
  • Page 72 HVC-PD Depot E-Bus Charger Installation Guide 5.6.7. Connect the PE wire between the Power Cabinets Preconditions: • Parts (per cabinet): 35/M12 tubular cable lug (1x). • Tools: wire cutter, wire stripper, crimp pliers, spanner (size 19), torque wrench (size 19).
  • Page 73 HVC-PD Depot E-Bus Charger Installation Guide 5.7.1. Remove the protection cover Remove the protection plate (A) by loosening the screws (B) (4x). Put the protection plate and screws in a safe location as it will be installed again later on.
  • Page 74 HVC-PD Depot E-Bus Charger Installation Guide 5.7.3. Install the protection cover Take the protection plate that was removed in Remove the protection cover on Page 73. Place the protection plate (A) back over the DC connector blocks and secure the plate by the screws (B) (4x).
  • Page 75 HVC-PD Depot E-Bus Charger Installation Guide Route the AC utility cable to the terminal block (A). Refer to the figure for the preferred cable route inside the cabinet (only within the HVC 150). Route the Interlock cable(s) to the terminal block (B). Refer to the figure for the preferred cable route inside the cabinet.
  • Page 76 HVC-PD Depot E-Bus Charger Installation Guide 5.8.3. Connect the Interlock cable for the HVC 150 kW system Interlock cable connection in the primary HVC 150: Terminal block Interlock cable from/to ACS Control Module (ACM) Move the cable towards the terminal block (A).
  • Page 77 HVC-PD Depot E-Bus Charger Installation Guide 5.8.4. Upgrade the Interlock connection to the HVC 300 kW system Interlock cable connection in the primary HVC 150: Terminal block Interlock cable from/to ACS Control Module (ACM) Interlock cable from/to secondary 1 HVC 150S Move the cables towards the terminal block (A).
  • Page 78 HVC-PD Depot E-Bus Charger Installation Guide Interlock cable connection in secondary 1 HVC 150S: Terminal block Interlock cable from/to primary HVC 150 Move the cables towards the terminal block (A). Strip 0.43 inch of the insulation from the ends of only the White and Brown wire! Crimp a ferrule onto the end of the White and Brown wire.
  • Page 79 HVC-PD Depot E-Bus Charger Installation Guide 5.8.5. Upgrade the Interlock connection to the HVC 450 kW system Interlock cable connection in secondary 1 HVC 150S: Terminal block Interlock cable from/to primary HVC 150 Interlock cable from/to secondary HVC 150S Interlock cable from/to secondary HVC 150S Move the cables towards the terminal block (A).
  • Page 80 HVC-PD Depot E-Bus Charger Installation Guide Interlock cable connection in secondary 2 HVC 150S: Terminal block Interlock cable from/to secondary 1 HVC 150S Move the cables towards the terminal block (A). Strip 0.43 Inch of the insulation from the ends of only the White and Brown wire! Crimp a ferrule onto the end of the White and Brown wire.
  • Page 81 HVC-PD Depot E-Bus Charger Installation Guide 5.8.6. Connect the CAN cable NOTICE The CAN cable connection is only needed for the HVC 300 kW and 450 kW E-Bus Charger, see for more details section Cabling on Page 46. CAN cable connection in secondary 2 HVC 150S (in case of a HVC 450 kW system):...
  • Page 82 HVC-PD Depot E-Bus Charger Installation Guide CAN cable connection in secondary 1 HVC 150S: Terminal block CAN cable to primary HVC 150 CAN cable from secondary 2 HVC 150S (in case of a HVC 450 kW system) Move the cable towards the terminal block (A).
  • Page 83 HVC-PD Depot E-Bus Charger Installation Guide CAN cable connection in primary HVC 150: Terminal block CAN cable from secondary 1 HVC 150S Move the cable towards the terminal block (A). Strip 0.43 Inch of the insulation from the ends of the wires.
  • Page 84 HVC-PD Depot E-Bus Charger Installation Guide 5.9. Connect the communication cable Power Cabinet NOTICE The communication fiber cables to the ACS Control Module are only connected within the primary HVC 150 Power Cabinet, see for more details section Cabling on Page 46.
  • Page 85 HVC-PD Depot E-Bus Charger Installation Guide Remove the protection covers from the optical connectors. Connect the two Ethernet fiber cables (C) onto the module D2 (A): • Rx with Td D2; • Tx with Rd D2. Connect the two CAN bus fiber cables (D) onto module D1 (B): •...
  • Page 86 HVC-PD Depot E-Bus Charger Installation Guide 5.11. Installation of the Pantograph 5.11.1. Before unpacking The Pantograph will be delivered within a wooden box. NOTICE Unloading Pantograph The delivery truck only unloads the pallet carrying the Pantograph. The delivery truck will not move the Pantograph to its final location. The placement of the Pantograph to its final location is the responsibility of the contractor.
  • Page 87 HVC-PD Depot E-Bus Charger Installation Guide WARNING Before mounting the pantograph affix a rope or cable to the crossbar of the upper arm and to the base frame so that the pantograph cannot lower unexpected out of housed position. WARNING Make sure that personnel cannot be falling from the platform when working at height.
  • Page 88 HVC-PD Depot E-Bus Charger Installation Guide Use the right existing lifting eyes on the Pantograph, lifting eyes (C) for crane or lifting eyes (D) for forklift truck (see picture above), to lift-up the Pantograph. NOTICE When lift-up the Pantograph by using a forklift truck, remove onside of the wooden box.
  • Page 89 HVC-PD Depot E-Bus Charger Installation Guide Fix the base frame (B) with M16 bolts, washers and spring washers (4x) (provided by the customer). Tighten the bolts with a tightening torque of 110 N·m. Check that the Pantograph’s base frame (B) is planar and bear on without tension.
  • Page 90 HVC-PD Depot E-Bus Charger Installation Guide Move the Pantograph’s base frame (G) to the right side bracket (B) and aligned with the appropriate holes within the bracket (B) on which the Pantograph will be mounted. Fix the base frame (G) with M16 bolts (H), spring washers (I) and washers (J) (2x) (provided by the customer) to the bracket (B).
  • Page 91 Before mounting the WiFi antenna, see section WiFi antenna position in relation to the bus on Page 36. The following steps are described assuming the ABB Pantograph mounting bracket is used. However, the following steps can also be used with a self-constructed structure for mounting the WiFi antenna.
  • Page 92 RFID tack on the roof of the bus. The following steps are described assuming the ABB Pantograph mounting bracket is used. However, the following steps can also be used with a self-constructed structure for mounting the RFID unit.
  • Page 93 HVC-PD Depot E-Bus Charger Installation Guide CAUTION Do not pollute the environment with plastic and cardboard packing. Depollute these things according the regional applicable regulations as well as environment-friendly. 5.13.1. Connect the PE wire to the Pantograph frame Preconditions: •...
  • Page 94 HVC-PD Depot E-Bus Charger Installation Guide 5.13.2. Connect the ACS PE and CP/PE wire to the Pantograph Preconditions: • Parts: 35/M12 tubular cable lug (1x), 16 AWG/M12 ring tongue crimp ferrule (2x), M12 x 40 Class 8.8 bolt (2x), M12 washer (4x), M12 spring washer (2x), M12 nut (2x), heat- shrink 2:1 Ø...
  • Page 95 HVC-PD Depot E-Bus Charger Installation Guide Strip 20 mm of the insulation from the end of the wire. Attach the cable lug (C) to the end of the PE wire (D). 10. Fit the M12 bolt (E) with washer (F) and the PE wire (D).
  • Page 96 HVC-PD Depot E-Bus Charger Installation Guide 5.13.3. Connect DC cables to Pantograph Preconditions: • Parts: 185/M12 tubular cable lug (2x, 4x or 6x ), M12 x 40 Class 8.8 bolt (2x, 4x or ), M12 washer (4x, 8x or 12x...
  • Page 97 HVC-PD Depot E-Bus Charger Installation Guide 10. Screw from the other side of the DC- connector (A) the DC- wire(s) (if needed), washer(s) (G), spring washer(s) (H) and nut(s) (I) on the bolt(s) (E). 11. Tighten the bolt/nut connections with a tightening torque of 78 N·m.
  • Page 98 HVC-PD Depot E-Bus Charger Installation Guide Loosen the PE connector screw of the insert (F). Insert the PE wire (green/yellow) into the insert PE connector. Tighten the connector screw of the insert (F). 10. Slide the hood (D) over the insert (F) and lock it with the included screw.
  • Page 99 HVC-PD Depot E-Bus Charger Installation Guide Functional description Wire number Insert position connector (F) ACS L Heater ACS N Heater Green/yellow NOTICE Make sure the pins are locked inside the insert and cannot pushed back. Slide the hood (D) over the insert (F) and lock it with the included screw.
  • Page 100 HVC-PD Depot E-Bus Charger Installation Guide 5.13.7. Connect the RFID cables to the RFID unit (optional) Route the RFID Ethernet cable (C) and the RFID Power cable (D) to the RFID unit. Remove the protection cover caps from the connectors (A and B).
  • Page 101 HVC-PD Depot E-Bus Charger Installation Guide Lift the Junction Box out of the box. Place both ACS Control Module and Junction Box on the ground with its top facing up. 5.15. Install ACS Control Module and Junction Box onto wall Preconditions: •...
  • Page 102 HVC-PD Depot E-Bus Charger Installation Guide 5.15.1. Using the wall-mounting brackets (only for ACM) The ACS Control Module can be easily mounted by using the wall-mounting brackets, see Wall-mounting brackets for safe wall fixing on Page 20. Determine whether the wall-mounting brackets (D) should be mounted horizontally or vertically, see also section Workflow for wall mounting on Page 45.
  • Page 103 HVC-PD Depot E-Bus Charger Installation Guide 10. Tighten the wood-wire-bolts with a tightening torque of 10 – 15 N·m. 5.15.2. Direct wall mounting Unlock the locks (B) of the ACS Control Module. Open the door (A). Loosen the screws (E) (6x) of the Junction Box (C).
  • Page 104 M8 bolt connections. The delivery of the earth-rail are not in the scope of supply of ABB. 5.16.1. Connect the PE wire of the ACS PE Cut the PE wire to the correct length to reach the PE rail.
  • Page 105 HVC-PD Depot E-Bus Charger Installation Guide Remove the M8 bolt and washers from the PE rail. Fit the bolt (C) with toothed washer (D), the PE wire (B) and the contact washer (E). Insert the bolt fitted with the PE wire into the PE rail.
  • Page 106 HVC-PD Depot E-Bus Charger Installation Guide 5.16.4. Connect the PE wire from the Junction Box Cut the PE wire to the correct length to reach the PE rail. Do not make the wire routing too tight, or too loose. Strip 20 mm of the insulation from the end of the wire.
  • Page 107 HVC-PD Depot E-Bus Charger Installation Guide 5.16.6. Install lighting protection (optional) Cut the wire of the lighting protection cable to the correct length to reach the PE rail. Do not make the wire routing too tight, or too loose. Strip 20 mm of the insulation from the end of the wire.
  • Page 108 HVC-PD Depot E-Bus Charger Installation Guide 5 – 10 mm EMO switch 5 – 10 mm Beacon 5 – 10 mm Distance sensor 5 – 10 mm Temperature sensor 10 -17 mm RFID Power cable 13 – 21 mm Communication (fibers) 13 –...
  • Page 109 HVC-PD Depot E-Bus Charger Installation Guide 5.17.2. Connect the DC+ power in- and output cables Preconditions: • Parts: 185/M12 tubular cable lug (2x, 4x or 6x ), heat-shrink red 2:1 Ø 25.4 mm. • Tools: wire cutter, wire stripper, crimp pliers, spanner (size13 and 18), torque wrench (size 13 and 18).
  • Page 110 HVC-PD Depot E-Bus Charger Installation Guide Loosen and remove the cable gland’s (#14 - #18 and #20, depending on the system configuration see also Charge system configurations on Page 47) nuts, including the cover caps inside the gland, for the DC+ power cables.
  • Page 111 HVC-PD Depot E-Bus Charger Installation Guide 15. Place the protection cover back on the DC contactors. 16. Hand tighten the screws of the protection cover. 17. Tighten the cable gland’s nut to secure the DC power cables. 5.17.3. Connect the DC- power in- and output cables in Junction Box Preconditions: •...
  • Page 112 HVC-PD Depot E-Bus Charger Installation Guide Attach cable lug (C) at the end of the wires (D) and use the heat-shrink to cover the crimp connection. Remove the M12 bolts, washers and nuts from the bus-bar (G). Fit the bolt (E) with flat washer (F) and the wire (D) (6x).
  • Page 113 HVC-PD Depot E-Bus Charger Installation Guide 5.17.4. Connect the DC- OVP Sensing wire from Junction Box Loosen and remove the cable gland’s (#22) nut for the DC- OVP Sensing wire. Slide the cable gland’s nut over the DC- OVP Sensing wire.
  • Page 114 HVC-PD Depot E-Bus Charger Installation Guide 11. Tighten the connector screw of GND-rail (C). 12. Insert the other 3 wires into the connectors of circuit breaker (B). ● From left to right: L1 (brown), L2 (black), L3 (grey). 13. Tighten the connector screws of circuit breaker (B) with a tightening torque of 3.0 N∙m.
  • Page 115 HVC-PD Depot E-Bus Charger Installation Guide Route the communication fiber cables to module U5 (A) and U7 (B). Remove the protection covers from the optical connectors. Connect the two Ethernet fiber cables (C) onto module (A): • Rx with Td U5;...
  • Page 116 HVC-PD Depot E-Bus Charger Installation Guide 5.17.8. Connect the RFID cables NOTICE This section is not required if the RFID module is not present. Preconditions: • Parts: 0.25 x 6 ferrule (2x), heat-shrink 2:1 Ø 12.7 mm. • Tools: wire cutter, wire stripper, crimp pliers, screwdriver.
  • Page 117 HVC-PD Depot E-Bus Charger Installation Guide Tighten the nut of the gland to secure the RFID Power cable. Strip 150 mm insulation from the cable (C). Place a 40 mm long heat-shrink at the end of the cable (C). 10. Strip 11 mm of the insulation from the ends of only the Brown and Blue wire! 11.
  • Page 118 HVC-PD Depot E-Bus Charger Installation Guide Route the cables through the right glands to the connector blocks (X2, X3 and X4), with sufficient cable length (do not make the cable routing too tight, or too loose). Tighten the nuts of the glands to secure the cables.
  • Page 119 HVC-PD Depot E-Bus Charger Installation Guide 5.18. Close the door of the ACS Control Module Preconditions: • Close the door (A). Close the locks (B). 5.19. Mounting the emergency unit The emergency unit (EMO) must be placed on an easily accessible position for the operator.
  • Page 120 HVC-PD Depot E-Bus Charger Installation Guide 5.20. Mounting the beacon It is advisable to mount the beacon for the operator to a visible location. Mount the beacon on a wall or construction (location depended), see for mounting option section Charger state indicator light (beacon) on Page 22.
  • Page 121 CAUTION Warranty It is not permitted to move the whole or parts of the HVC-PD Depot E- Bus Charger after the commissioning. If the whole or parts of the HVC- PD Depot E-Bus Charger is moved without contacting the ABB Service department, the warranty will be considered void.
  • Page 122 SAT checklist, • list of remaining items. After the CAF has been signed, the customer support will be handled by the ABB Service department. If there are any remaining items, they can be noted on the CAF document, together with the agreed solution and the expected date of completion.
  • Page 123 Secure against resetting. 7.2. Cleaning of the cabinet The Power Cabinet and ABB Pole is powder coated. This coating must be kept in good condition. Clean the Power Cabinet and ABB Pole three times a year in the following way: •...
  • Page 124 HVC-PD Depot E-Bus Charger Installation Guide NOTICE When the HVC-PD Depot E-Bus Charger is exposed to rain, it is sufficient to clean it twice a year. CAUTION Do not apply high-pressure water jets. Water may leak into the Power Cabinet. If a high-pressure water jet has been used, make sure that the inside of the Power Cabinet is dry.
  • Page 125 HVC-PD Depot E-Bus Charger Installation Guide 8. Technical Specification 8.1. Electrical specification complete 150 kW system Input Supply voltage 3-phase, 400 V AC: PE, L1, L2, L3 Input voltage range 400 V AC ± 10% Input frequency range 50 Hz ± 4%...
  • Page 126 HVC-PD Depot E-Bus Charger Installation Guide 8.3. Electrical specification complete 450 kW system Input Supply voltage 3-phase, 400 V AC: PE, L1, L2, L3 Input voltage range 400 V AC ± 10% Input frequency range 50 Hz ± 4% Maximum power dissipation 520 kVA Power factor (cos ᵠ)
  • Page 127 -10 ºC to +70 ⁰C Storage conditions Indoors, dry CAUTION Warranty Warranty will be considered void when the HVC-PD E-Bus Charger is damaged while badly stored at the customer's location. 8.6. Certifications Certifications for complete system Certificate number pole: 2388-CPR-0044...
  • Page 128 HVC-PD Depot E-Bus Charger Installation Guide 9. Appendix Dimensions Power Cabinet Dimensions ACS Control Module Dimensions Junction Box Dimensions Pantograph Dimensions Pantograph mounting brackets Dimensions Concrete Foundation Power Cabinet Dimensions Metal Foundation Power Cabinet Power Cabinet – Outline with Foundation...
  • Page 129 HVC-PD Depot E-Bus Charger Installation Guide A. Dimensions Power Cabinet Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 129 of 145...
  • Page 130 HVC-PD Depot E-Bus Charger Installation Guide Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 130 of 145...
  • Page 131 HVC-PD Depot E-Bus Charger Installation Guide B. Dimensions ACS Control Module Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 131 of 145...
  • Page 132 HVC-PD Depot E-Bus Charger Installation Guide C. Dimensions Junction Box Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 132 of 145...
  • Page 133 HVC-PD Depot E-Bus Charger Installation Guide D. Dimensions Pantograph Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 133 of 145...
  • Page 134 HVC-PD Depot E-Bus Charger Installation Guide E. Dimensions Pantograph mounting brackets Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 134 of 145...
  • Page 135 HVC-PD Depot E-Bus Charger Installation Guide Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 135 of 145...
  • Page 136 HVC-PD Depot E-Bus Charger Installation Guide F. Dimensions Concrete Foundation Power Cabinet Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 136 of 145...
  • Page 137 HVC-PD Depot E-Bus Charger Installation Guide Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 137 of 145...
  • Page 138 HVC-PD Depot E-Bus Charger Installation Guide G. Dimensions Metal Foundation Power Cabinet Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 138 of 145...
  • Page 139 HVC-PD Depot E-Bus Charger Installation Guide H. Power Cabinet – Outline with Foundation Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 139 of 145...
  • Page 140 HVC-PD Depot E-Bus Charger Installation Guide I. Signal connection diagram For HVC 150 kW system Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 140 of 145...
  • Page 141 HVC-PD Depot E-Bus Charger Installation Guide For HVC 300 kW system Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 141 of 145...
  • Page 142 HVC-PD Depot E-Bus Charger Installation Guide For HVC 450 kW system Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 142 of 145...
  • Page 143 HVC-PD Depot E-Bus Charger Installation Guide J. Ground overview of the system Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 143 of 145...
  • Page 144 HVC-PD Depot E-Bus Charger Installation Guide K. WEEE disposal – 2012-19/EU Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 144 of 145...
  • Page 145 HVC-PD Depot E-Bus Charger Installation Guide NOTES Document: v1.3 / Document No.: 6AGA000008-0604-EN | Date: 06-14-2020 Page 145 of 145...