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ABB PD Control Box Depot Operation And Installation Manual
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ABB PD Control Box Depot Operation And Installation Manual

ABB PD Control Box Depot Operation And Installation Manual

For hvc 200/300/360 multi-outlet cabinet
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A B B CH A R G I N G S TATI O N
Operation and installation manual
PD Control Box depot (CE version)
for HVC 200/300/360 multi-outlet cabinet

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Summary of Contents for ABB PD Control Box Depot

  • Page 1 A B B CH A R G I N G S TATI O N Operation and installation manual PD Control Box depot (CE version) for HVC 200/300/360 multi-outlet cabinet...
  • Page 2 "Operation and installation manual" - "PD Control Box depot (CE version)" ATTENTION – IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety instructions that must be followed during the installation and maintenance of the equipment. ATTENTION – SAVE THESE INSTRUCTIONS This document is a part of the equipment, keep it in a safe place near the equipment for easy reference during installation, operation and maintenance.

  • Page 3: Table Of Contents

    Table of contents 1. Introduction and general information 3.7.1 RFID (Radio Frequency IDentification) device Long distance communication kit Disclaimer and warranty conditions Long distance communication Function and target of this document 3.9.1 Overview inside - Long distance kit Language 3.10 Working principles How to use this document 3.11 Optionals...
  • Page 4 “Operation and installation manual” - “PD Control Box depot (CE version)” 7. Electrical connection 9. Maintenance and troubleshooting Electrical connection PD Control Box - Pantograph Down Maintenance schedule for the owner Troubleshooting 7.1.1 Protective Earth connections 7.1.2 DC power cables connection 7.1.3 Control Pilot (CP) and Control Pilot PE (CP PE) connection...

  • Page 5: Introduction And General Information

    User Disclaimer and warranty conditions ABB E-mobility shall not be liable for any damages, losses, costs or expenses resulting from the improper handling of the EVSE, in particular resulting from non compliance with the instructions of this document and other applicable regulations and standards (e.g. installation, transport, occupational health and other safety standards).

  • Page 6: Language

    “Operation and installation manual” - “PD Control Box depot (CE version)” The document is applicable to this EVSE (Including all variants and options): • PD Control Box depot (CE version) NOTE The Control Box is part of HVC systems and must be connected to the HVC 200-300-360 power cabinet.

  • Page 7: Terminology

    Terminology Description Network operating center Facility of the manufacturer to do a remote check on the correct operation of of ABB EV Infrastructure the EVSE Cabinet Enclosure of the EVSE, including the components on the inside Extra length of cable from the top of the foundation so that the cable length...

  • Page 8: Document Revision History

    “Operation and installation manual” - “PD Control Box depot (CE version)” Document revision history Version Date Description January 2024 Preliminary version NOTE Latest version of the manual is available online (ABB Library ID 9AKK108468A7470)

  • Page 9: Safety

    Safety 2. Safety This chapter contains the safety instructions which must obey during installation, commissioning, operation and maintenance of the equipment. Always obey and follow the reading order of instruction exactly as described in this manual to prevent injury or damage to the equipment. The manufacturer accepts no liability for failure to comply with the instructions for a correct installation and cannot be held responsible for any other upstream or downstream equipments.

  • Page 10: Liability

    “Operation and installation manual” - “PD Control Box depot (CE version)” Liability The manufacturer declares that the equipment complies with the regulations currently in force in the country of installation and has issued the corresponding declaration of conformity. The manufacturer is not liable for damages, losses, costs or expenses incurred by any user of the EVSE (e.g.

  • Page 11: Intended Use

    Safety Intended use This equipment has the exclusive function of fast EV charging and it is intended to be used both in indoor and outdoor environments. NOTE Depot charging (overnight): truck and bus fleets that have short daily operating cycles often rely on overnight charging at the depot when a lower power can be used to charge the vehicles.

  • Page 12: Residual Risks

    “Operation and installation manual” - “PD Control Box depot (CE version)” 2.2.2 Residual risks Despite the warnings and safety systems, there are still some residual risks that cannot be eliminated. These risks are listed in the following table with some suggestions to prevent them:...
  • Page 13 Safety Symbol Description Rotating parts that can cause a risk of entrapment Hot surface that gives risk of burn injuries With signal word ‘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 procedure General safety instructions for a procedure Information about spare parts that are necessary for a procedure...

  • Page 14: Personal Protective Equipment

    “Operation and installation manual” - “PD Control Box depot (CE version)” Personal protective equipment A Personal Protective Equipment (PPE) is clothing or equipment designed to protect/reduce employees from exposure to work place hazards and the risk of injury. Symbol Description...

  • Page 15: Safety Instructions During Installation

    Safety 2.5.2 Safety instructions during installation • Make sure that there are any supply voltages on the input cables during the complete installation procedure. • Keep unqualified personnel at a safe distance during installation. • Only use electrical wires of sufficient gauge and insulation to handle the rated current and voltage demand.

  • Page 16: Discard The Evse Or Parts Of The Evse

    The manufacturer (ABB E-mobility) 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 17 Safety For the regulations of individual countries, refer to the national and international certification bodies as follows: Country Standard Description ASTM American Society for Testing and Materials International Organization for Standardization CENELEC European Committee for Electrotechnical Standardization Italy Comitato Elettrotecnico Italiano International International Electrotechnical Commission International...

  • Page 18: Description

    “Operation and installation manual” - “PD Control Box depot (CE version)” 3. Description This chapter contains information about the models, details of the equipment, characteristics and technical data, overall dimensions and equipment identification. A description of the equipment characteristics is provided to identify its main components and specify the technical terminology used in the manual.

  • Page 19: Type Plate - Identification Of Equipment

    Global ID MODEL CODE CODE Global ID Weight www.abb.com FOR USE WITH ELECTRICAL VEHICLES Refer to manual ABB E-Mobility B.V. Heertjeslaan 6, IPXX 2629 JG Delft, The Nederlands MADE IN ITALY Prod. date WW YYYY Ref. Description Country of origin...

  • Page 20: System Overview

    “Operation and installation manual” - “PD Control Box depot (CE version)” System Overview System Overview without Power Supply Box (Optional): Ref. Part Function Power distribution board To supply the electrical energy to EVSE HVC 200/300/360 Power cabinet 2 or 4 outputs. Output power 200, 300 or 360 kW...

  • Page 21: Overview

    Ref. Part Function Power cabinet To change the AC input power into DC output power PD Control Box depot To control the charge process The EV of which the batteries need to be charged Parking space Parking space Pantograph down...

  • Page 22: Pd Control Box - Overview

    “Operation and installation manual” - “PD Control Box depot (CE version)” PD Control box - Overview 3.5.1 Overview - Outside Ref. Part Function Front door To access the internal parts of the EVSE Charging status beacon To show the EVSE status based on the colours...

  • Page 23: Overview - Inside

    Cable conduits To arrange and protect the cables inside the box AC aux. power supply breaker To turn on/off the PD Control Box depot 24 Vdc power supply DC SPD protection fuses To connect Interlock, DC guard, Power supply AC aux.
  • Page 24 “Operation and installation manual” - “PD Control Box depot (CE version)” Ref. Part Function Protection barrier. If removed, it allows access to the Internal removable cover internal connection and components To connect DC negative pole coming from HVC- DC in (-)

  • Page 25: Overview - Cable Glands

    Description 3.5.3 Overview - Cable glands Ref. Part Function DC+ input Positive DC input pole DC+ input Positive DC input pole PE from HVC-200/300/360 Power Main Protective Earth cable Cabinet Lighting protection Earth Lighting Protective Earth cable (earth electrode) DC- input Negative DC input pole DC- input Negative DC input pole...

  • Page 26: Overview - Pantograph Down

    “Operation and installation manual” - “PD Control Box depot (CE version)” 3.5.4 Overview - Pantograph Down The Pantograph Down is a part of the charging station, which consists of the Off-Board charging station and the On-Board charging equipment. The Pantograph Down is a component of the Off-Board charging station. The device is connected in place at the HVC 200/300/360 Power Cabinet and, as a current transmitter, it is lowered to supply the On-Board charging equipment with electric current.
  • Page 27 Description DC -contact rail To transfer the current to the EV charging equipment Protective Earth (PE) connection To connect the Protective Earth (PE) cable coming from PD Control point Depot ceiling bracket To mount the Pantograph Down to the depot roof/structure (ABB6AGC113049) RFID unit (Optional) Optional device for Radio-Frequency IDentification...

  • Page 28: Evse Status Beacon

    “Operation and installation manual” - “PD Control Box depot (CE version)” EVSE status beacon The EVSE is equipped with a beacon on the front of the box, that indicates the status based on the colours. In the table are described the main status:...

  • Page 29: Authorization To Charge

    Description Authorization to charge 3.7.1 RFID (Radio Frequency IDentification) device RFID is a device installed on the PD Kit and is an additional safety measure to prevent the pantograph from moving down when no bus is parked underneath. It is mandatory when two charge poles or pantographs are positioned within a distance of 12 m or less from each other (centre-to-centre of each pantograph).

  • Page 30: Long Distance Communication Kit

    “Operation and installation manual” - “PD Control Box depot (CE version)” Long distance communication kit Long distance communication The CAN/Ethernet communication between the Power Cabinet and PD Control Box is done via an ethernet cable (standard configuration). However, in case of installations with distance more than 100 m between Power Cabinet and PD Control Box, the communication based on a fiber optic communication line, can be used.

  • Page 31: Working Principles

    Description 3.10 Working principles Colours Description Bold lines: power connection Thin lines: auxiliary power connection Ethernet line Control signal or monitoring signal CAN bus...

  • Page 32: Optionals

    “Operation and installation manual” - “PD Control Box depot (CE version)” 3.11 Optionals 3.11.1 Transport Frame In order to lift and transport the pantograph down with a forklift is recommended to use the optional transport frame. Ref. Part Function ABB6AGC109154...

  • Page 33: External Emergency Stop Button

    Description 3.11.2 External Emergency stop button The external Emergency stop button (EMO) is used to stop the charge session in case of an emergency (the beacon will become red). The Emergency stop button is equipped with 2 contacts normally closed (NC) Ref.

  • Page 34: Transport, Handling And Unpacking

    “Operation and installation manual” - “PD Control Box depot (CE version)” 4. Transport, handling and unpacking In this section are explained all the transport specification, including handling and unpacking procedures of the EVSE. Chapter recipients: • Owner • Installer...

  • Page 35: Transport Of The Evse - Preliminary Operation

    Transport, handling and unpacking Transport of the EVSE - Preliminary operation A transport company delivers the EVSE close to the site. The movement of the EVSE to its final location is their responsibility. NOTE If you need to store the equipment before installation, obey the ambient conditions for storage. DO NOT store the equipment in a location exposed to severe weather conditions (e.g.

  • Page 36: Move The Packaged Evse

    “Operation and installation manual” - “PD Control Box depot (CE version)” Move the packaged EVSE 4.2.1 Move the PD Control Box and the PD Bracket with a forklift truck • Move the forks of the forklift truck in the gaps of the pallet.
  • Page 37 Transport, handling and unpacking • Fork on the right side as indicated on the package • Do not stand near the EVSE during handling • Pay attention to the unevenness of the floor • Pay attention to the side/forward slopes of the floor...

  • Page 38: Hoist The Pantograph Down

    “Operation and installation manual” - “PD Control Box depot (CE version)” 4.2.3 Hoist the Pantograph Down WARNING • Risk of pinching or crushing, the equipment is heavy • Make sure that the hoisting equipment can lift the equipment safely • Obey the safety instructions that apply to the hoisting equipment •...

  • Page 39: Unpacking

    • Do a visual check for damage on the outside and inside of the boxes. • Make sure that all parts are delivered according to the order. • If you find damage or the parts are not according to the order, contact the local representative of the manufacturer (ABB EV Infrastructure).

  • Page 40: Unpacking The Pantograph Down

    “Operation and installation manual” - “PD Control Box depot (CE version)” 4.3.2 Unpacking the Pantograph Down WARNING Packaging elements (wood, cardboard, cellophane, staples, adhesive tape, straps, etc.) may cause cuts and/or injuries if not handled with care. They should be removed with the proper equipment.

  • Page 41: Move The Unpacked Evse

    Transport, handling and unpacking Move the unpacked EVSE The unpacked components of the equipment can be moved with: • The PD Control Box can be moved manually or using a forklift • The PD Bracket can be moved manually or using a forklift •...
  • Page 42 “Operation and installation manual” - “PD Control Box depot (CE version)” • Install the PD bracket on the Pantograph using the 6 holes on the bracket and on the Pantograph. The fastners to be used are in the kit ABB6AGC109932 (Fastner kit) M16x30 •...
  • Page 43 Transport, handling and unpacking 4.4.1.2 Transport frame assembly • Install the 2 vertical supports on the base (7 bolts and washers). Repeat the operation for the second one. • Install the connecting bracket between the two holders (4 bolts and washers on each side). •...
  • Page 44 “Operation and installation manual” - “PD Control Box depot (CE version)” • Lift the Panto Down and install it on the transport frame. • Install fastners between transport frame and Panto Down.
  • Page 45 Transport, handling and unpacking • Move the forks of the forklift truck in the gaps of the transport frame. WARNING Risk of pinching or crushing, the equipment is heavy • Obey the safety instructions that apply to the forklift truck. •...

  • Page 46: Components Supplied With The Evse

    “Operation and installation manual” - “PD Control Box depot (CE version)” Components supplied with the EVSE 4.5.1 Components supplied with the PD Control Box Component Description Quantity Keys to open the EVSE door DC cable lug (M10, 185mm 2 (1 on the positive...

  • Page 47: Components Supplied With The Pd Bracket (Abb6Agc113049)

    Transport, handling and unpacking 4.5.3 Components supplied with the PD Bracket (ABB6AGC113049) Depot ceiling half bracket. To install: • LED Tower Lights • Wireless antenna • RFID device (opt.) Depot ceiling half bracket. To install the Pantograph Down LED Tower Lights Wireless antenna RFID device (optional) 1 (optional)

  • Page 48: Access To The Internal Parts

    “Operation and installation manual” - “PD Control Box depot (CE version)” 5. Access to the internal parts In this section are illustrated all the acces procedures. Chapter recipients: • Installer...

  • Page 49: Pd Control Box

    Access to the internal parts PD Control Box To make the electrical connections is necessary to access the internal parts of the PD Control Box. Hazardous voltage Make sure that only qualified persons have access to the door key. NOTE There is one unique door key for the PD Control Box.

  • Page 50: Close The Doors

    “Operation and installation manual” - “PD Control Box depot (CE version)” • Remove the 5 cross-head screws (B) of the internal protective cover (C). • Disconnect the connector (A) on the wiring harness of the fan installed on the protective cover.

  • Page 51: Installation

    Installation 6. Installation In this section are illustrated all the installation procedure. Chapter recipients: • Owner • Installer...

  • Page 52: Pd Control Box - Installation

    “Operation and installation manual” - “PD Control Box depot (CE version)” PD Control Box - Installation 6.1.1 Wall/Structure installation of the Control Box The installation of the Control Box can be done on a wall or roof structure: NOTE This type of installation can be done using the supplied wall brackets.

  • Page 53: Install The Brackets On The Control Box

    Installation 6.1.3 Install the brackets on the Control Box NOTE Install all four brackets vertically. • Align the hole in the brackets (A) with the hole in the box (B). • Install the washer (D) on the screw (C) and install the bracket on the back of box. 6.1.4 Install the Control Box on the wall/structure •...

  • Page 54: Pantograph Down - Installation

    “Operation and installation manual” - “PD Control Box depot (CE version)” • Depending on the type of anchor chosen, drill the required 4 holes to mount the bracket. WARNING It is an installer’s responsibility to choose appropriate type of anchors. The choice must be based on the type of support (concrete wall, wood or other support) and their ability to support at least 4 times the equipment’s weight.

  • Page 55: Ceiling Space Requirements

    NOTE The correct positioning of the PD Kit must be evaluated together with ABB E-mobility technical sales support. Contact ABB Sales department Taking in consideration that the PD Kit should be positioned on the center of on-board contact rails, the EV has the following tolerance to be positioned under the pantograph.

  • Page 56: Pd Bracket Assembly On The Pantograph

    “Operation and installation manual” - “PD Control Box depot (CE version)” Kneeling of the bus will cause a displacement of the contact rails on top of the bus of about 200 mm (3.5° angle with a the height of the bus 3280 mm). This should also be taken into account when determining the minimum or maximum distance between pole and bus.
  • Page 57 Installation • Install the PD bracket on the Pantograph using attachment points. NOTE The fastners are preinstalled on the bracket. M16x30 NOTE M16x14 The RFID is an oprional device. Skip this step if you don’t plan to install it. • Connect the cables (supplied) on the RFID device: - RFID Ethernet cable (A) - RFID Power Supply cable (B)
  • Page 58 “Operation and installation manual” - “PD Control Box depot (CE version)” • If not present, connect the cable on the LED Tower light. • Take the second half bracket and install the LED Tower lights on Install in the suggested direction as shown in the figure.
  • Page 59 Installation • Cut a 35 mm PE wire (A) to connect the bracket (B) to the pantograph down connection points. • Strip the insulation and crimp cable lugs on the PE wire. Cable lug bracket side (B) Hole for a M8 bolt (Ø9) Cable lug pantograph side (C) Hole for a M10 bolt (Ø11)

  • Page 60: Ceiling Installation Of The Pantograph Down

    “Operation and installation manual” - “PD Control Box depot (CE version)” 6.2.5 Ceiling installation of the Pantograph Down The Pantograph Down is mounted using the installation holes on the bracket. The exact positioning of the Pantograph Down is dependent on the position of contact rails on the vehicle roof (is therefore necessary to know the on-board charging equipment position of EV).
  • Page 61 Installation • Depending on the type of anchor chosen, drill the required 4 holes (A) to mount the bracket. WARNING It is an installer’s responsibility to choose appropriate type of anchors. The choice must be based on the type of support (concrete wall, wood or other support) and their ability to support at least 4 times the equipment’s weight.

  • Page 62: Electrical Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” 7. Electrical connection In this section are listed all the electrical connection procedure. Chapter recipients: PD Control Box Pantograph • Installer DC Power OUT DC Power 185 mm (max)
  • Page 63 Electrical connection 7.1.1.1 PE wires (output) connections on the PD Control Box Depot The connection of the PE wires, inside the PD Control Box, must be made on the busbar (A): - PE wire to the pantograph PE pole passing through the cable gland (#21)
  • Page 64 “Operation and installation manual” - “PD Control Box depot (CE version)” • Install the wires on the PE busbar using the M10 nut and washers (preinstalled on the busbar). • Tighten the nut to the following torque: Torque (Nm) PE busbar 20 Nm •...
  • Page 65 Electrical connection Connection procedure of the PE wire on the PE pole (A): • Take one of the PE wire (C) coming from the PD Control Box and cut it to the correct length to reach the pantograph PE pole (A). •...

  • Page 66: Dc Power Cables Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” 7.1.2 DC power cables connection This connection is used to bring DC power from the PD Control Box to the Pantograph down which will be used for charging the EV.
  • Page 67 Electrical connection • Open the box and remove the internal protective cover. Refer to “5. Access to the internal parts”. • Unscrew and remove the ring of: - Cable gland (#22) for the DC positive cable to the pantograph pole. - Cable gland (#20) for the DC negative cable to the pantograph pole.

  • Page 68: Control Pilot (Cp) And Control Pilot Pe (Cp Pe) Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” Connection procedure of the DC cables on the Pantograph poles (A) (B): • Take the DC cables (C) (D), coming from the PD Control Box, and cut it to the correct length to reach the pantograph DC poles (A) (B).
  • Page 69 Electrical connection 7.1.3.1 Control Pilot (CP) and Control Pilot PE (CP PE) connections on the PD Control Box Depot The Control Pilot (CP) and Control Pilot PE (CP PE) connection, inside the PD Control Box, must be made on X3 screw terminal blocks passing the cable through the dedicated cable gland (#18).
  • Page 70 “Operation and installation manual” - “PD Control Box depot (CE version)” 7.1.3.2 Control Pilot (CP) and Control Pilot PE (CP PE) connections on the Pantograph down The connection of the Control Pilot (CP) and Control Pilot PE (CP PE), on the Pantograph down (coming from the...

  • Page 71: Acs And 24V Dc Cable Connection

    The ACS and 24V cable is supplied. The cable has preinstalled connector on the Pantograph side. PD Control Box Pantograph + PD Bracket It must be connected on the switchbox on the Pantograph and cutted on PD Control Box Depot side. 35 mm...
  • Page 72 “Operation and installation manual” - “PD Control Box depot (CE version)” • Open the box and flip the internal protective cover. Refer to “5. Access to the internal parts”. • Route the ACS and 24V DC cable through the dedicated cable conduit.

  • Page 73: Heater Power Supply Cable Connection

    Wireless antenna Wireless antenna Antenna Cable, N-type connector N-type connector -U6:X2 7.1.5.1 Heater power supply connections on the PD Control Box Depot RFID Ethernet RFID Ethernet Ethernet Cable; dedicated cable RFID device etherneth port -U5: X2 The Heater power supply connections, inside the PD Control Box, must be made on X3 screw terminal blocks...
  • Page 74 “Operation and installation manual” - “PD Control Box depot (CE version)” • Open the box and flip the internal protective cover. Refer to “5. Access to the internal parts”. • Route the Heater power supply cable through the dedicated cable conduit.

  • Page 75: Electrical Connection Pd Control Box - Pantograph Bracket Devices

    Electrical connection PD Control Box Pantograph Control Pilot Control Pilot 7.2 Electrical connection PD Control Box - Pantograph CP - CP pole plate CP: -X3:11 CP_PE: -X3:12 PE - PE pole plate Bracket devices Shield: -X3:13 PD Control Box Pantograph CAUTION Electrical connection on Pantograph down is carried out on the exposed metallic connection AC Power to heater...

  • Page 76: Wireless Antenna Cable Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” PD Control Box Pantograph AC Power to heater AC Power to heater Dedicated cable (supplied) 7.2.1 Wireless antenna cable connection L: -X3:22 N: -X3:23 PE: -X3:24 *dedicated cable harness The wireless antenna connection allows to communicate with the EV.

  • Page 77: Rfid (Optional) Cable Connection

    Electrical connection AC Power to heater AC Power to heater Dedicated cable (supplied) L: -X3:22 N: -X3:23 PE: -X3:24 7.2.2 RFID (optional) cable connection *dedicated cable harness The RFID (optional) connection allows to enable the charging session via RFID technology. PD Control Box PD Bracket Wireless antenna...
  • Page 78 “Operation and installation manual” - “PD Control Box depot (CE version)” Connection procedure of the RFID 24V DC power supply cable: • Open the box and flip the internal protective cover. Refer to “5. Access to the internal parts”. • Route the RFID 24V DC power supply cable through the dedicated cable conduit.

  • Page 79: Led Tower Light Cable Connection

    AC Power to heater AC Power to heater Dedicated cable (supplied) Electrical connection L: -X3:22 N: -X3:23 PE: -X3:24 *dedicated cable harness 7.2.3 LED Tower Light cable connection PD Control Box PD Bracket Wireless antenna Wireless antenna Antenna Cable, N-type connector N-type connector -U6:X2 RFID Ethernet...

  • Page 80: Terminal Description

    “Operation and installation manual” - “PD Control Box depot (CE version)” Connection procedure of the RFID 24V DC power supply cable: • Open the box and flip the internal protective cover. Refer to “5. Access to the internal parts”. • Route the LED Tower Light cable through the dedicated cable conduit.

  • Page 81: Electrical Installation Hvc 200/300/360 - Pd Control Box

    Electrical connection 7.3 Electrical installation HVC 200/300/360 - PD Control Box Protective earth (PE) connection HAZARDOUS VOLTAGE Before carrying out any operation, check that any external switch of voltage sources (downstream to the EVSE) are in OFF position and check for input voltage absence! The Main Protective Earth (coming from the Power Cabinet) must be connected to point marked with the Protective Earth (PE) symbol and using a cable with an appropriate conductor cross-section for the maximum ground fault current that the system might experience.

  • Page 82: Connect The Main Pe

    “Operation and installation manual” - “PD Control Box depot (CE version)” In compliance with standards it is necessary to install a main earthing cable between Power Cabinet and the protective earth terminal of the PD Kit, with a minimum section as indicated in the table below:...

  • Page 83: Connect The Lighting Protection Earth

    Electrical connection 7.4.2 Connect the Lighting Protection Earth In some cases additional Lighting Protection Earth is required (one electrode of maximum 10 Ω) at the PD Kit side (based on local safety and electrical regulations). NOTE If the grid is TT based, consult the grid owner. It is possible that an extra 0,9 Ω electrode will be required.
  • Page 84 “Operation and installation manual” - “PD Control Box depot (CE version)” The connection of the AC auxiliary power supply must be made on F1 circuit breaker and X1 screw terminal blocks. Connection specifications F1 _ Connecting capacity 0.75 ... 25 mm² (flexible wires with ferrule) F1 _ Torque 2.8 Nm...

  • Page 85: Dc Input Power Connection

    Electrical connection DC input power connection This connection is used to bring DC power from the HVC-200/300/360 Power Cabinet to the Control Box which will be used for charging the EV. Power cabinet PD Control box HVC-200/300/360 185 mm (max) DC Power DC Power IN 185 mm...

  • Page 86: Interlock And Dc Guard Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” • Open the box and remove the internal protective cover. Refer to “5. Access to the internal parts”. • Unscrew and remove the ring of: - Cable gland (#01) and/or (#05) for the DC positive cables coming from Power Cabinet.
  • Page 87 Electrical connection The connection of the Interlock and DC Guard signals, coming from the power cabinet, must be made on X2 screw terminal blocks. Connection specifications 0.22 ... 4 mm² wire with non insulated ferrule X2 _ Connecting capacity 0.22 ... 2.5 mm² wire with insulated ferrule X2 _ Torque 0.6 ±...
  • Page 88 “Operation and installation manual” - “PD Control Box depot (CE version)” • Open the box and flip the internal protective cover. Refer to “5. Access to the internal parts”. • Unscrew and remove the ring of the cable gland (#11).

  • Page 89: Ethernet Connection (Standard Communication Line)

    If an on-site internet connection is available, the charger will be automatically configured to transmit AC Power supply AC Power supply telemetry data to the ABB EVCI Cloud without the need to install any additional devices (the logging 3x2.5 mm L: -F1:2 functionality is already integrated into the charger by default).
  • Page 90 “Operation and installation manual” - “PD Control Box depot (CE version)” NOTE • Check that the cable requirements are respected before starting the installation: A. The max diameter of ethernet cable must be 7 mm. B. The max length of ethernet...

  • Page 91: Use Of The Long Distance Communication (Optical Fiber)

    Electrical connection Power cabinet PD Control box HVC-200/300/360 AC Power supply AC Power supply 3x2.5 mm L: -F1:2 N: -F1:4 PE: -X1:1 • Open the cover on the connector X3-2. • Connect the Ethernet cable to the Ethernet connector X3-2. Power cabinet PD Control box HVC-200/300/360...

  • Page 92: Optical Fiber Connection

    “Operation and installation manual” - “PD Control Box depot (CE version)” Ref. Part Function Protection tube To protect the cable when it is routed through conduit OM3 fiber optic cable For long distance communication line Metal finish To install the cable inside the M32 cable gland (length 50 – 80 mm)

  • Page 93: Hvc 200/300/360 Reconfiguration For Optical Fiber Communication

    Electrical connection 7.8.3 HVC 200/300/360 reconfiguration for optical fiber communication In order to ensure the communication, using optical fiber, the following operation must be performed on the HVC 200/300/360 power cabinet. • Open the front door (A) and the internal door (B) on the HVC 200/300/360.

  • Page 94: Ethernet Connectors

    “Operation and installation manual” - “PD Control Box depot (CE version)” • Connect the cable(s) (previously removed from the ARM XL board) to the Ethernet connectors installed on the DIN rail. See table below: -X84 From Ethernet ARM XL board...

  • Page 95: Emergency And External Stop Buttons Connection (Optional)

    Ethernet communication (standard) Electrical connection Ethernet communication Ethernet cable Cat6 shielded -X3:2 Emergency and External Stop buttons connection (optional) The connection of the external optional devices must be made on X2 screw terminal blocks passing the cable Power cabinet PD Control box through the cable gland (#09).
  • Page 96 “Operation and installation manual” - “PD Control Box depot (CE version)” • Open the box and remove the internal protective cover. Refer to “5. Access to the internal parts”. • Unscrew and remove the ring of the cable gland (#09).

  • Page 97: Operation And Correct Use

    Operation and correct use 8. Operation and correct use This chapter will give instruction on the correct use of the EVSE. Chapter recipients: • Owner • Installer • User...

  • Page 98: Prepare For Commissioning

    4G LTE bands 2 (1900 MHz), 4 (1700/2100MHz), or 12 (700 MHz). NOTE The Charger supports SIM cards provided by ABB only. Any other types of SIM cards are not supported. The signal strength must be greater than -85 dBm and should be measured with a cellular network signal meter.

  • Page 99: Prepare Before Use

    • If parked outdoors, remove snow from the roof of the bus before starting the charging session • If necessary, use additional heating unit surrounding the rails on top of the bus (not part of the ABB offering). To support the operation in the winter the contact rails on the EV Bus/Truck (on-board charging equipment) Max 2.5°...

  • Page 100: Admitted Pantograph Position Tolerance

    “Operation and installation manual” - “PD Control Box depot (CE version)” 8.3.1 Admitted pantograph position tolerance The electrical vehicle has a certain freedom degree to position under the PD Kit. Working range of the pantograph contact rails respect to the center of each rail of the on-board charging...

  • Page 101: Charge Session

    Operation and correct use Charge session 8.4.1 Start a charge session • The EV arrives at depot for charging. Wireless communication between EV and PD Kit is not yet active. • The EV is close to the PD Kit. Wireless communication between EV and PD Kit is active. •...
  • Page 102 “Operation and installation manual” - “PD Control Box depot (CE version)” In the table are described the main status: LEDs color Description The EVSE is in idle mode and ready for use: The beacon of the EVSE is solid green...

  • Page 103: Stop A Charge Session

    Operation and correct use 8.4.2 Stop a charge session If the charging session is complete, the bus driver has to interrupt the charging process to continue the operation. • Bus driver releases the handbrake. Pantograph goes automatically up. NOTE Time between bus indicating a stop charge (release handbrake) until clearance to drive away is 5 seconds.

  • Page 104: Maintenance And Troubleshooting

    “Operation and installation manual” - “PD Control Box depot (CE version)” 9. Maintenance and troubleshooting In this section the user will be istructed on maintenance and cleaning procedures. Preliminary requirements Owner...

  • Page 105: Maintenance Schedule For The Owner

    Maintenance and troubleshooting Maintenance schedule for the owner Frequency Task Procedure Clean: • Cleaning agent with pH value between 6 and 8 • Remove dirt by hand. Do not use abrasive tools. • Remove rough dirt by rinsing with low-pressure tap water.

  • Page 106: Technical Data

    “Operation and installation manual” - “PD Control Box depot (CE version)” 10. Technical data This chapter contains information about the models, details of the equipment, characteristics and technical data, overall dimensions and equipment identification. A description of the equipment characteristics is provided to identify its main components and specify the technical terminology used in the manual.

  • Page 107: Technical Data Specification - Pd Kit

    Technical data 10.1 Technical data specification - PD Kit 10.1.1 Technical data - PD Control Box Depot PD Control Box Depot Product information and main features Depot charging (Overnight) Opportunity charging Sequential charging Connectible external devices ext. Emergency stop button, ext. Charge stop button,...

  • Page 108: Technical Data - Pantograph Dp40

    “Operation and installation manual” - “PD Control Box depot (CE version)” 10.1.2 Technical data - Pantograph DP40 DepotPANTO DP40 Product information and main features Equipment designation DepotPANTO Design single arm Type DP40 Nominal system voltage 1500V DC Charging current - (end station)

  • Page 109: Cable Specifications

    Ambient Temperature range -40...70 °C Identification Acc. to DIN 47100 T568-B PD Control Box Depot - Fiber optic cable for Long distance communication (coming from HVC 200/300/360) Specifications Fiber optic Number of fibers 4 (2 for Tx and Rx connection, 2 for spare)

  • Page 110: Torque Specification

    “Operation and installation manual” - “PD Control Box depot (CE version)” 10.1.4 Torque specification PD Control Box Depot Depot charge box dual outlet Parameter Specification [Nm] DC connection points on the busbars F1 - AC auxiliary circuit breaker X1 screw terminal block 0.5 ±...

  • Page 111: Attachments

    Attachments 11. Attachments In this section additional tecnical drawing, specification, schematics are given. NOTE If you need further information, please contact your local manufacturer service dept. Refer to section “Manufacturer and contact data”...

  • Page 112: Overall Dimensions

    “Operation and installation manual” - “PD Control Box depot (CE version)” 11.1 Overall dimensions 11.1.1 Pantograph Down Overall dimensions of Pantograph Down (including bracket). NOTE The dimensions are expressed in millimeters. 689.5 536.5 BUS TRAVEL ASS’Y MTG SLOTS, DIRECTION 4 PL 1751.5...

  • Page 113: Pantograph Down - Pantograph Working Range

    Attachments 11.1.2 Pantograph Down - Pantograph working range NOTE The dimensions are expressed in millimeters.

  • Page 114: Pantograph Down - Transport Frame

    “Operation and installation manual” - “PD Control Box depot (CE version)” 11.1.3 Pantograph Down - Transport frame NOTE The dimensions are expressed in millimeters. Ref. Part Function ABB6AGC109154 Transport Frame for Pantograph Down...

  • Page 115: Pd Control Box Dopot

    Attachments 11.1.4 PD Control Box Dopot Overall dimensions of PD Control Box depot. NOTE The dimensions are expressed in millimeters.

  • Page 116: Pd Control Box Depot - Connection Diagram

    “Operation and installation manual” - “PD Control Box depot (CE version)” 11.2 PD Control Box depot - Connection diagram The connection diagram shows all necessary and optional connections of the PD Control Box depot.
  • Page 117 — https://new.abb.com/ev-charging...