ABB Terra DC wallbox Installation Manual

or a reference to one or more standards that may be generally relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document support all of the features of the described or referenced standard. In order to determine the specific features supported by a particular ABB product, the reader should consult the product specifications for the particular ABB product. ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB products described in this document. The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unau- thorized purpose. Copyrights All rights to copyrights, registered trademarks, and trademarks reside with their respective owners. Copyright © 2020 ABB. All rights reserved.

1.1 Preface ................................................................................................................................................... 6 1.2 Intended document users ....................................................................................................................... 6 1.3 Terra DC Wallbox hardware ordering details............................................................................................ 6 1.4 Signs ...................................................................................................................................................... 7 1.4.1 Owner responsibilities ............................................................................................................ 8 1.4.2 Tilting and handling ................................................................................................................ 9 1.4.3 Sharp edges ........................................................................................................................... 9 1.4.4 Electric hazards ...................................................................................................................... 9 1.4.5 Installation safety ................................................................................................................. 10 1.5 Environment and disposal of waste....................................................................................................... 10 2 Description of the product.............................................................................................................................. 11 2.1 Overview of the system ........................................................................................................................ 11 2.1.1 Complete overview .............................................................................................................. 11 2.1.2 External view ....................................................................................................................... 12 2.1.3 Inside view ........................................................................................................................... 13 3 Installation Planning and Design..................................................................................................................... 14 3.1 Internet connection .............................................................................................................................. 14 3.1.1 Internet via cellular connection ............................................................................................ 14 3.1.2 Internet via ethernet connection .......................................................................................... 14 3.2 Electrical requirements ......................................................................................................................... 15 3.2.1 Required electrical grid configuration ................................................................................... 15 3.2.2 Overcurrent protection device .............................................................................................. 17 3.2.3 Conduit for power input wires .............................................................................................. 17 3.2.4 Specification for power input wires ...................................................................................... 17 3.2.5 Conduit for ethernet cable ................................................................................................... 18 3.2.6 Specification for ethernet cable ............................................................................................ 18 3.3 DC Wallbox placement ......................................................................................................................... 18 3.3.1 Charging cable reach ............................................................................................................ 18 3.3.2 DC Wallbox position with respect to parking space ............................................................... 19 3.3.3 Required space for installing and maintaining the DC Wallbox...............................................20 3.3.4 Ventilation and airflow required for the DC Wallbox ............................................................. 21 3.3.5 Considerations for where to position DC Wallbox vertically ................................................... 21 4 Installation instructions .................................................................................................................................. 23 4.1 About construction............................................................................................................................... 23 4.2 Instruction for a wall bearing ................................................................................................................ 23 4.2.1 Mounting on a pedestal ....................................................................................................... 23 4.3 Power feed ........................................................................................................................................... 23 4.4 Internet connection .............................................................................................................................. 23

5.1 Receiving the Wallbox .......................................................................................................................... 24 5.2 Unpacking the charging and mounting preparations ............................................................................. 25 5.2.1 Unpacking ............................................................................................................................ 25 5.2.2 Mounting preparations ........................................................................................................ 26 5.3 Move cabinet to position ...................................................................................................................... 26 5.3.1 Options ................................................................................................................................ 26 5.4 Mounting the Terra DC Wallbox ............................................................................................................ 26 5.4.1 Mounting the Terra DC Wallbox ............................................................................................ 27 5.4.2 Install cable gland(s) or connect conduit to the unit. ............................................................. 31 5.5 Connect cables ..................................................................................................................................... 33 5.5.1 Connect PE of power cable ................................................................................................... 33 5.5.2 Connect power cable............................................................................................................34 6 Commissioning ...............................................................................................................................................36 6.1 Commissioning preparation .................................................................................................................. 36 7 Maintenance and Cleaning of the cabinet ...................................................................................................... 37 7.1 Recommended Periodic maintenance ................................................................................................... 37 7.2 Cleaning of the cabinet ......................................................................................................................... 37 8 Technical Data ................................................................................................................................................38 8.1 Electrical data ....................................................................................................................................... 38 8.2 Mechanical data ................................................................................................................................... 39 8.3 Environment ........................................................................................................................................ 39 8.4 Certifications ........................................................................................................................................ 39 9 Contact information ...................................................................................................................................... 40 10 Appendix A – Mounting points ....................................................................................................................... 41 10.1 Terra DC Wallbox Charger wall mounting .............................................................................................. 41 11 Appendix B - Disposal instruction .................................................................................................................. 42 11.1 Directive on Waste Electrical and Electronic Equipment (WEEE – 2012/19/EU) ......................................42 12 Appendix C – Pedestal requirements ............................................................................................................. 43

charging protocol of European and North American car makers. CHAdeMO DC fast charging method for electric vehicles. Contractor Entity hired by the owner / site operator to do engineering, civil and electrical installation work. DC Direct Current. EV Electric Vehicle. Grid provider Company responsible for the transportation and distribution of electricity. HMI Human Machine Interface; the display/screen on the charger. NOC ABB Network Operating Centre; remotely checks the correct functioning of the charger. Owner The legal owner of the charger. OCPP Open Charge Point Protocol. Open standard for communication with charge stations. PE Protective Earth. PPE Personal Protective Equipment. Equipment such as safety shoes, helmet, glasses, gloves. RCD Residual Current Device. Breaks the connection if a residual current is detected. RFID Radio-Frequency IDentification. RFID is a communication technology by means of radio waves to transfer data over a very short distance between a reader and an electronic tag or card. Site operator This entity is responsible for the day to day control of the charger. The site operator can be the owner, but not necessarily. User The owner of an electric vehicle, who uses the Charge Station to charge that vehicle.

The Terra DC Wallbox charging station is an easy to install DC fast charger for electric vehicles. Fast chargers are electrical installations with high electric currents. Therefore, the installation must be planned carefully, and must be done by certified personnel only (according to local standards). Local regulations shall take precedence if they list different installation requirements than prescribed in this Installation Manual. The Terra DC Wallbox is offered in a variety of configurations and with multiple connector types. The different versions are described in section 1.3. Before installing the Terra DC Wallbox, read this installation guide carefully and attentively. Be sure to follow all instructions when installing the charger. ABB is not responsible for any damage caused by not following or incorrectly executing the instructions described in this manual. 1.2 Intended document users This document is intended to be used by: • Customers who have purchased a Terra DC Wallbox or customers in the process of ordering and require additional details on installation. • Contractors who are responsible for site preparation and/or installation of a Terra DC Wallbox. 1.3 Terra DC Wallbox hardware ordering details ABB’s Terra DC Wallbox is offered in the following configurations. Version 1-Phase 3-Phase Terra DC Wallbox C UL X X Terra DC Wallbox J UL X Terra DC Wallbox CJ UL X X C CCS-1 (Combo) standard J CHAdeMO standard CJ CCS-1 (Combo) standard and CHAdeMO standard All variations are offered with charging cable lengths of 7 meters (23 ft). The Terra DC Wallbox comes with the standard connector holsters as shown.

2020-12 7/4 4 Optional connector holsters shown below may be purchased separately with the order code details shown below. Charging cable type ABB order code CCS-1 ABB6AGC076604 CHAdeMO ABB6AGC076601 1.4 Signs The following signs are used on the equipment and in this manual: DANGER Hazardous voltage Identifies a hazard that could result in severe injury or death through electrocution. WARNING Various Identifies a hazard that could result in severe injury or death.

2020-12 8/44 WARNING Rotating parts Identifies a hazard that could result in injury due to the presence of rotating or moving parts. WARNING Pinch Hazard Identifies a hazard that could result in injuries, in which some body parts are pinched or crushed. CAUTION Various Identifies a hazard that could result in damage to the machine, other equipment, and/or environmental pollution. CAUTION Environmental damage Identifies a hazard that could result in environmental damage and/or environmental pollution. NOTICE Contains remarks, suggestions or advice. 1.4.1 Owner responsibilities The owner and site operator are required to: • Operate the charge station with the protective devices installed and to ensure all protective devices are correctly installed after carrying out installation or maintenance work. • Write an emergency plan that instructs people what to do in case of emergency. • Prepare the site where the charge station will be installed according to the requirements described in this guide. • Ensure there is sufficient space around the charger to carry out maintenance work. • Appoint a person responsible for the safe operation of the charge station and for the coordination of all work. The owner is cautioned that changes or modifications not expressly approved by ABB could void the owner’s authority to operate the equipment and 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 as a result of: an accident, misuse or abuse of this product or unauthorized modifications, repairs or alterations to this product, or failure to strictly comply with ABB’s operating and maintenance instructions.

2020-12 9/44 1.4.2 Tilting and handling WARNING Heavy equipment The Terra DC Wallbox weighs approximately 70 kg. Follow the handling Instructions: 1. Two people are recommended for the installation and wall-mounting of a Terra DC Wallbox. 2. Do not drop the Terra DC Wallbox. 1.4.3 Sharp edges WARNING Sharp metal edges There could be sharp metal edges inside the Terra DC Wallbox. It is recommended to wear mash protecting gloves when working inside the charger. 1.4.4 Electric hazards DANGER Hazardous voltage The Terra DC Wallbox contains conductors under hazardous electrical voltages. The grid terminals on the internal DIN rail may carry hazardous voltages, even if all circuit breakers are switched off.

2020-12 10/44 1.4.5 Installation safety DANGER Hazardous voltage Instructions: 1. Always switch off the input circuit feeding the unit, (external disconnect or breaker) before performing any installation, disassembly, repair or replacement of components. Follow appropriate requirements for safe work practices, including but not limited to NFPA-70e. 2. Perform a voltage check to ensure electrical power is disconnected from the system. 3. Only ABB certified technicians should commission the Terra DC Wallbox. 4. When the system is in an open or dangerous condition, do not allow unqualified persons to go near it. Instruct and warn people about the potentially harmful high voltages. 5. The installation and maintenance personnel must supply their own lighting equipment because the Terra DC Wallbox has no lights inside the cabinet. 6. Always connect the Protective Earth (PE) first, before connecting the other power input wires. 7. Be sure to properly and securely reassemble the Terra DC Wallbox’s enclosure after installation or service operations. 8. When handling the equipment, a proper lifting device should be used in accordance with your local EHS policies. 1.5 Environment and disposal of waste NOTICE Always follow the local rules and regulations regarding disposal of any (non-reusable) Terra DC Wallbox parts.

2020-12 11/44 2 Description of the product 2.1 Overview of the system 2.1.1 Complete overview Example of a complete installation A Power distribution board of the owner B Cables in conduit C Terra DC Wallbox D Parking space for charging E Electric vehicle

2020-12 12/44 2.1.2 External view A Display / HMI E Emergency stop button B RFID card reader F AC input connection point for Conduit C DC Charging cable G Air inlet D Air outlet H Standard Holster (included) I Optional Holster (purchased separately) Standard charging cable holster supplied with DC wallbox Optional charging cable holster sold separate from DC wallbox

2020-12 13/44 2.1.3 Inside view A AC input board D Cable gland for DC output(2x) B CPI and IMI boards E Cable gland for AC input C External Fan (2x)

2020-12 14/44 3 Installation Planning and Design This section provides several considerations for the DC Wallbox installation planning and design, which are to be made by the customer to ensure a successful project. 3.1 Internet connection ABB requires an internet connection to the DC Wallbox to conduct remote service operations including, over- sight of the product during the warranty period, diagnosis and troubleshooting of issues, and performing soft- ware firmware update. Not having internet connection to the DC Wallbox may severely impact, or even void, the product warranty and/or ABB’s service level agreement (SLA). It is the installer’s responsibility to ensure reliable internet connection to the DC Wallbox is made. Contingency planning and the associated costs are the responsibility of the installer. 3.1.1 Internet via cellular connection The preferred method of establishing internet connection to the charger is using the charger’s standard featured hardware with ABB’s Charger Connect service offering, which provides internet access via Vodafone’s 4G LTE wireless network. In the USA, Vodafone primarily roams on the AT&T and T-Mobile 4G LTE networks. It is expected that a cellular availability test is performed prior to construction to ensure there is reasonable signal quality to at least one of the AT&T and T-Mobile 4G LTE bands 2 (1900 MHz), 4 (1700/2100MHz), or 12 (700 MHz). The signal strength must be greater than -85dbm and should be measured with a cellular network signal meter, such as a Squid-4G or Sure Call device. Handheld mobile phones are not recommended for assessing signal strength since they are not reliable measuring devices. The DC Wallbox only supports SIM cards provided by ABB. Customer procured SIM cards are not supported. 3.1.2 Internet via ethernet connection Internet connection to the charger may be performed by connecting an ethernet cable to the charger from other on-site IT infrastructure. However, due to the scope of work required for integrating this solution to ensure se- cure communication, this method is typically not preferred. ABB may require additional commissioning fees if ethernet cable method for establishing internet is used, de- pending on the situation. Please contact your ABB sales representative for more details. See sections 3.2.5 and 3.2.6 for more details on connection of conduit carrying ethernet cable and specification of the ethernet cable.

2020-12 15/44 3.2 Electrical requirements CAUTION The installation company is responsible to design and install the electrical installation according to the local regulations. 3.2.1 Required electrical grid configuration The DC Wallbox may be ordered with either a 1-phase or 3-phase input variant. It is essential that the DC Wall- box is installed in the proper electrical grid configuration. The allowable grid configurations are shown in the three figures below. Please observe the 3-phase variant DC Wallbox supports only one grid configuration and the 1-phase variant DC Wallbox supports two different grid configurations. For the 1-phase variant DC Wallbox, ABB recommends the electrical designer to consider power distribution phase balancing design requirements. Electrical grid configuration required for 3-phase, DC Wallbox UL variant (3ø, 480Y/277V input) 3-phase 480Y/277V Terra DC Wallbox Neutral Grounding Electrode Conductor 277V 480V Line 1 Line 2 Line 3 Neutral Ground Line 1 Line 2 Line 3 40A fused switch or circuit breaker

2020-12 16/4 4 One of two electrical grid configurations acceptable for use with 1-phase, DC Wallbox UL vari- ant (1ø, 208V input) Neutral Grounding Electrode Conductor 120V 240V 1-phase 240V Terra DC Wallbox Line 1 Line 2 Ground Line 1 Line 2 125A fused switch or circuit breaker One of two electrical grid configurations acceptable for use with 1-phase, DC Wallbox UL vari- ant (1ø, 240V input) 1-phase 208V Terra DC Wallbox Neutral Grounding Electrode Conductor 120V 208V Line 1 Line 2 Ground Line 1 Line 2 Line 3 125A fused switch or circuit breaker 208V

2020-12 17/44 NOTICE: The grid connections shown for the various configurations of the DC Wallbox are mandatory. Failure to adhere to these instructions may partially or fully void the product warranty, result in a costly site visit to reconfigure the grid configuration, and/or cause several site visits for the DC Wallbox commissioning. ABB is not responsible for scheduling delays and additional costs from not properly planning the installation. If ABB is contracted to perform the DC Wallbox commissioning, ABB observes the right to charge additional money for more than one site visit required for the commissioning due to an initial, improper installation of the DC Wallbox. Important steps to ensure project success include: 1. Identify the grid configuration at the location where the DC Wallbox will be installed. If the grid configuration available is not okay for use with the DC Wallbox, then determine how to establish the required grid connection. A transformer solution offered by ABB is available to derive the required grid configuration when the required grid configuration is not available. Contact your local ABB sales representative for more details. 2. Select the 1-phase or 3-phase variant of the DC Wallbox according to Section 1.3 titled Terra DC Wallbox hardware ordering details based on Step 1 above. 3. Carefully execute a project plan to ensure the correct variant of DC Wallbox is used on the project and that the project site’s grid configuration is compatible with the DC Wall- box. 4. Verify the actual grid configuration the DC Wallbox is installed in matches the described criteria during the DC Wallbox commissioning. 3.2.2 Overcurrent protection device Each variant of the DC Wallbox is recommended to be fed by the circuit breaker or fuse ratings shown below. • 1-phase, 208-240V DC Wallbox variant: 2-pole, 125A circuit breaker or fuses • 3-phase, 480Y/277V DC Wallbox variant: 3-pole, 40A circuit breaker or fuses 3.2.3 Conduit for power input wires Each variant of the DC Wallbox supports up to a 1-1/4” trade size conduit connection. 3.2.4 Specification for power input wires The exact size and type of wires used must be defined by the customer and be protected by customer provided overcurrent protection according to local codes and regulations. The input terminals for both 1-phase and 3-phase UL variants of the DC Wallbox accept a range of wire sizes from 10 AWG to 0 AWG. Wire terminals are rated 75C. The 3-phase UL variant DC Wallbox requires Three (3) phase wires, One (1) neutral wire, and One (1) wire for protective earth. (3W+N+G) The 1-phase UL variant DC Wallbox requires Two (2) phase wires and One (1) wire for protective earth. (2W+G)

2020-12 18/44 All wires for 3-phase and 1-phase variants of the DC Wallbox may connect directly to the ABB provided termi- nals, with exception to the protective earth wire for the 3-phase variant DC Wallbox. The protective earth wire for the 3-phase variant DC Wallbox requires for the installer to crimp a terminal onto it using the terminal manu- facturer’s recommended crimp procedure and tool. The integrity of the electrical grounding is essential. Ensure that the equipment grounding terminal is used in the device and an actual grounding conductor is installed to provide a path back to the source upstream panel. (Do not use the conduit or raceway as the sole equipment grounding conductor). 3.2.5 Conduit for ethernet cable The DC Wallbox does not have a hole designated for a conduit carrying only an ethernet cable to connect to. If ethernet cable solution is required for an installation, please contact your ABB sales contact person to review ethernet cable entry solutions. 3.2.6 Specification for ethernet cable If the cellular connection is not available, ethernet connection must be made to the charger using a shielded 8P+PE ethernet cable with RJ45 connectors. Additional recommendations include: • Maintain distance of 75 meters or less. Distances over 75 meters require a custom engineered solution. • Minimum bandwidth: upload: 128 kb/s download: 4 Mb/s • 99.9% availability • 600V rated cable that may route beside input power wires for short distances 3.3 DC Wallbox placement Placement of the Terra DC Wallbox must be carefully determined by accounting for charging cable reach, DC Wallbox position with respect to parking space, bollards and wheel stops, ventilation and working clearances, and other local codes and regulations (e.g. ADA requirements in the USA). 3.3.1 Charging cable reach The Terra DC Wallbox charging cables are available in lengths of 3.5 or 7 meters. The charging cables exit the charger enclosure on both the right and left sides. The cables and the connectors mounted on the cables are dif- ferent depending on the charging standard and vary in flexibility. The figure below shows an example of a dual connector charger with both types of connector and the corre- sponding reach area. The green circle with a continuous line describes the CHAdeMO cable 3.5m and the red circle with a continuous line describes the CCS cable 3.5m. The broken lines indicate the same cable types with a length of 7 meters (23 ft).

2020-12 19/4 4 3.3.2 DC Wallbox position with respect to parking space The charging inlets on a vehicle can be located at different positions depending on the manufacturer. The most common vehicles have inlets located either on the front or in the back on either the left or right side. This makes some charger placements with respect to the parking space more favorable than others. Keep this in mind when designing a site. Below are examples of possible situations:

2020-12 20/44 3.3.3 Required space for installing and maintaining the DC Wallbox The Terra DC Wallbox requires a minimum space of 36” x 48”. This space is calculated as follows: - Charger size (H x W x D): 30.3 x 23 x 11.8 in - Bottom side 23.6” (15.75” from the Terra DC Wallbox in order to avoid obstacles for the electrical connection). - Left and right side 300mm/12”, in order to operate without obstacles on the lateral side of the Terra DC Wall- box. Note: The below dimensions are shown in millimeters.

2020-12 21/44 3.3.4 Ventilation and airflow required for the DC Wallbox The Terra DC Wallbox has an air inlet on the bottom side and an outlet on the top side. NOTICE Free air flow If necessary, take precautions to prevent snow or objects from blocking the inlets and outlets. 3.3.5 Considerations for where to position DC Wallbox vertically The below picture shows the height of the operable parts and display screen from the top and bottom of the DC Wallbox’ s enclosure (not accounting for piece on enclosure where the customer conduits connect to). It is the installer’s responsibility to use this information to define the height at which to install the DC Wallbox from the ground and to ensure compliance to local codes and regulations (e.g. ADA requirements in the USA).

2020-12 23/4 4 4 Installation instructions 4.1 About construction The construction phase includes all work required to prepare the location and ensure it is ready for the place- ment and connection of the Terra DC Wallbox charger. The construction phase can start when: • The wall preparation work is done. • All necessary permits are granted. • The grid connection is available. 4.2 Instruction for a wall bearing 1. Drill and tap 4 holes and insert the plug for fixation in the wall at the indicated positions (refer to tech- nical drawing in the Appendix A par. 10.1). For safety purposes, the number of recommended fixing screws is 4xST7.3x70. This is assuming the appropriate type of wall plugs are used (depends on wall’s characteristics, structure and type). It is the installer’s responsibility to choose an appropriate wall plug and to plan for a load of 820 N on each plug. 2. When selecting the area along the wall for installation, ensure the required free spaces for the Terra DC Wallbox cables are available (refer to section 3.4). 4.2.1 Mounting on a pedestal The Terra DC Wallbox can also be mounted on a pedestal. In order to achieve a safe installation, the minimum set of requirements are included in Appendix C – Pedestal requirements). For the ABB pedestal solution, contact your local ABB sales representative. 4.3 Power feed The power cable enters the charger from below. Use conduit, foam, or proper cable lugs and glands to prevent animals from entering the AC or Ethernet cable inlets. (Reference Section 3.2 for feeder specifications) 4.4 Internet connection The preferred method of communication is the wireless 4G modem integrated into the charger. A customer SIM card is not required. A subscription for the SIM card is provided by ABB for select countries. If there is no wireless signal available, a standard wired internet connection is required. (Reference Section 3.1, 3.2.5 and 3.2.6 for wiring and connection methods) • The connection must be available for the ABB service engineer and the NOC (Network Operation Cen- ter). • Please contact ABB (800.825.2556 option 2) for a specific configuration. If a separate internet connection is not used, please ensure the cable entry hole is closed to retain the IP54 grade of the cabinet and prevent insects and small animals from entering the cabinet.

2020-12 24/4 4 5 Receiving, Placing and connecting 5.1 Receiving the Wallbox The product is delivered by a transport company to a warehouse where it will be handed over. Transporting the Terra DC Wallbox to its final location (last mile service) is not included standard in the order. NOTICE The delivery truck unloads the pallet carrying the Terra DC Wallbox. The movement of the Terra DC Wallbox to its final location is the responsibility of the customer / contractor. Ensure the Terra DC Wallbox has not been shaken or tilted. • The cabinet is equipped with Shock Watch and Tilt Watch indicators. Checking the Shock Watch and Tilt Watch PLUS sensors: If the Shock Watch indicator is red, or the Tilt Watch PLUS indicator is tilted over 30°: 1. Do not refuse the delivery / receipt. 2. Make a notation on the delivery receipt and inspect cabinet for damage. 3. If damage is discovered, leave cabinet in original package and request immediate inspection from car- rier within 3 days of delivery. 4. Contact your local ABB office.

2020-12 25/4 4 5.2 Unpacking the charging and mounting preparations 5.2.1 Unpacking The packaging of the Terra DC Wallbox can be removed without the use of tools. Follow local regulations on dis- posal of packaging material. 1. Remove the plastic protection profiles. 2. Remove the bottom air grate grill and the lower frontal cover. 3. Remove the screws package and ensure it contains: • Four hex bolts M8 • Four screws M5 • Two bolts M5 4. Remove the wall frame. Bottom Cover Grill

2020-12 26/44 5. Remove the Terra DC Wallbox. (USE CAUTION TO NOT DAMAGE THE E-STOP BUTTON ON THE SIDE OF THE ENCLOSURE) 6. For all components above, remove the shrink wrap. 5.2.2 Mounting preparations Unpack the IP BOX and verify all the following items are present: • M8x30 8.8 hex bolts (4x) • M5 mounting screws (4x) • M5 mounting bolts (2x) • Wall frame • Frontal cover • Bottom grid cover 5.3 Move cabinet to position 5.3.1 Options A properly rated lifting devices should be used to move the Terra DC Wallbox from the delivery truck to the in- stallation location. DANGER Hazardous voltage Ensure the product’s power supply group main switch is set to the OFF position. Perform a voltage check to verify there is no electrical power on the cables or on the system. Secure the product from resetting. NOTICE Warranty Damage due to moving the cabinet to its position is not considered a warranty issue. 5.4 Mounting the Terra DC Wallbox Preconditions: • Tools: Spanner/Wrench size 17. • Guide the power cable through the central cable gland, and the Ethernet cable if required, through the smaller gland. Install the power wiring in the conduit/raceway that is connected to the unit. See below image for a typical conduit install make ready for installation of the Wallbox.

2020-12 27/4 4 • 5.4.1 Mounting the Terra DC Wallbox NOTICE A minimum of two people are required to lift a Terra DC Wallbox during installation. In general, local regulations should be followed as the maximum weight to be lifted may vary. 1. Carefully lower the Terra DC Wallbox onto its location. 2. Ensure cable(s) are not entrapped. 3. Place the wall frame in the correct position on the wall bearing by aligning the four holes of the charger with the corresponding holes on the wall bearing. 4. Tighten the four screws with stainless steel 8.8 hexagonal bolts. Mounting holes Mounting holes

2020-12 28/44 5. Place the unit on the wall frame by correctly aligning the 6 bolts (3 for each lateral side). 6. Tighten the two M5 bolts on the lower side of the unit. Pay attention to the internal fan power supply ca- ble. CAUTION: DO NOT SET SMALL OBJECTS ON TOP MESH COVER, ITEMS MAY FALL INTO THE COOLING FINS OR FAN COMPONENTS.

2020-12 29/44 7. Let the auxiliary power supply cable pass through the central gland and tighten it. 8. IMPORTANT, connect both of the cooling fans to their power connections before proceeding to close the covers. There are two connectors one for the left fan and one for the right fan.

2020-12 30/4 4 9. AFTER the completing wiring terminations, take the bottom cover grill and put it on the lower side of the unit and fix it by tightening two screws as shown in the following picture. Please note the 3-phase and 1- phase versions have a slightly different bottom grill assembly 10. Take the lower frontal cover and place it on the lower side of the unit. Secure it in place by tightening the two screws. 11. Center the holes on the plastic cover with the pins on the box.

2020-12 31/44 12. Place the central cover on the unit and secure it in place by tightening the two screws located on the left and right side of the cover. Center the bottom pins, rotate the cover, and tighten the 2 lateral screws. 5.4.2 Install cable gland(s) or connect conduit to the unit. The maximum diameter of the grid cable is 32 mm. The opening is pre-punched for a 1.25” trade size conduit. The minimum diameter of the grid cable is 22 mm with the standard fitted cable gland insert. Conduit Install shown as a comparison

2020-12 32/44 1. Slide the cable inside the grommets, ensure at least 10mm of cable external jacket inside the box (see notes at the end of this section, before sliding the cable inside the grommet. Allow at least 24 inches of wire from the conduit entry point to allow enough wire to route thru the internal grommet/cable glands and wrap around to the terminal blocks. (For the 3-phase version, remember to route the wires thru the ferrite) 2. Push the cables back through the gland plate, until sufficient cable length is left to reach the cable terminals. Ensure the PE cable is longer than the other cables. 208/240V 1-phase version Wire pass thru locations NOTE 1: For 3-phase versions a ferrite core is provided with the Wallbox (plastic bag within the package or strapped to the CCS-1 cable) and needs to be installed in commissioning phase. The Ferrite needs to be inserted in the AC in cable and located in the screw cable cover (see picture above, left). THE FERRITE IS REQUIRED TO MAINTAIN THE WARRANTY. NOTE 2: Two floating grounding cables are provided that are connected to the ground node. One cable must be con- nected between the to the wall frame PEM the other to the front lower cover in order to guarantee equal ground po- tential (see picture above, right). nOTE 480V 3-phase version Ferrite Location 3-phase version Wire pass thru location

2020-12 33/44 3. Slide the cable cover and tighten the two screws. If a wired internet connection is not used, please ensure the cable entry hole is closed, to assure the IP54 grade of the cabinet, and prevent insects and small animals to enter the cabinet. 5.5 Connect cables 5.5.1 Connect PE of power cable Preconditions: • Tools: Wire stripper pliers; wire-end lug pliers; wire-end lug. DANGER Hazardous voltage Make sure that the main switch of the power supply group for the product is set to the OFF position. Perform a voltage check and make sure that the electrical power is disconnected from the system. Follow recommended NFPA-70e procedures. Conduit Installation 1.25“ secured to bottom mounting area. 1-phase Version Shown 3-Phase Connection using flexible conduit

2020-12 34/44 1. Cut the PE wire of the power cable to the correct length (longer than the other phases) to reach the PE con- nector. NOTICE For safety, it is recommended that the PE wire is longer than the phase wires. This ensures the PE wire will be the last wire connected if the Terra DC Wallbox is moved by a collision. 2. Use wire stripper pliers to remove 20 mm of the insulation from the end of the PE wire and attach the cable lugs. 3. Pull the cover away from the connectors and remove them. 4. Loosen the bolts of the PE connector on the ground block. 5. Attach the PE wire onto the PE block. 6. Tighten the bolts. The advised torque value is 2 Nm. 5.5.2 Connect power cable Preconditions: • Tools: Wire stripper pliers; wire-end lug pliers; wire-end lugs. DANGER Hazardous voltage Ensure the product’s power supply group’s main switch is set to the OFF position. Perform a voltage check and ensure the electrical power is disconnected from the system. 7. Cut the 3 phase wires and the neutral wire of the power cable to the correct lengths to reach the connect- ors. 8. Use wire stripper pliers to remove 0.75 in of the insulation from the ends of the wires insert and terminate on the appropriate terminal block 9. Pull the covers away from the connectors and remove them. 10. Loosen the bolts of the connectors. 11. Attach the four wires on to their connectors as indicated on the label on the relative terminal block (see the following picture as example). • From left to right for the 3-phase unit (as showed in the following picture): N - terminal block blue, L1 - terminal block grey, L2 - terminal block grey, L3 - terminal block grey

2020-12 35/4 4 • From left to right for the 1-phase unit (as showed in the following picture): PE- terminal block green/yellow, L2 - terminal block grey, L1 - terminal block grey 12. Tighten the bolts. The advised torque value is 2.9Nm. 13. After terminating the wires, make sure to adjust the terminal blocks so they are properly aligned as misa- lignment can occur while applying proper torque to the connectors (as shown in 208/240V terminal layout above) L2 L1 208/240V 1-phase terminal layout

2020-12 36/4 4 6 Commissioning 6.1 Commissioning preparation Commissioning is the last phase necessary to get the Terra DC Wallbox operational. The purpose is to check the safe functioning of the charger for its operational purpose. An ABB certified service engineer or an ABB-trained engineer is required to perform the commissioning. During this commissioning, the safety and the functioning of the charger will be tested. ABB Form Titled “SI-TWBCE- 001 UL CSAT Procedure DC Wallbox” (Charger System Acceptance Test) should be used for the commis- sioning process as it contains the checklist and contact information for activation of the charger warranty. Before the service engineer can start, the following conditions must be met: • All work described in Preparation, Construction and Placement and connection is complete with Power available. • A local technician is present for assistance and to switch on the power. • Internet access must be available in case 4G is not functional. • A Combo compliant electric vehicle must be available for testing CCS charging. • A CHAdeMO compliant electric vehicle must be available for testing the CHAdeMO charging. • Any electric vehicle for instructing the site operator. NOTICE Warranty : It is not allowed to move the Terra DC Wallbox, after it is commissioned. In case the Terra DC Wallbox is moved without approval from ABB, the warranty will be considered void. In case of relocation please contact the local ABB Service department. Commissioning is executed according to the CSAT checklist, this check list can be found in the Helios Suite Ser- vice tool that is available to the certified commissioning engineers or their supervising ABB organization. The fol- lowing data is required for input: • End-user Contact person (Create a contact if it doesn’t exist). • Charger address (Check the site address, it will be the address the charger was shipped to). • Coordinates longitude and latitude for plots on the maps. If there are more chargers at 1 location, make sure the coordinates are slightly different (at least 0,0001 degrees) to prevent being displayed on the same location. • Site name if this is useful for better recognition (example: Shell petrol station Amsterdam). • External fuse of the charger. • SAT (Site Acceptance Test) date. Location remarks (any special remarks about the site, e.g. behind a gate, no photo cameras allowed etc.). Add a picture of the surrounding of the charger, upload the local CAF document A4 on the page of the charger in PDF. Change Deliver status to . After completing the Site Acceptance Test, ABB’s Network Operation Center will be triggered to perform a final check on the connection and configuration of the charger. Upon approval the charger will be operational and initialized for use.

2020-12 37/44 7 Maintenance and Cleaning of the cabinet 7.1 Recommended Periodic maintenance A. Following NFPA-70e procedures, de-energize unit, open cover, inspect air filter, clean or replace as needed. B. Check input connections and terminations for proper toque values C. Check Grounding resistance D. Exercise input breaker and output DC breakers E. Open HMI cover, inspect capacitors and fuse connections. F. Clean interior with a HEPA vacuum. G. Blow out rear cooling fins and remove any debris H. Reassemble unit, energize verify input voltage, perform a charging session. I. Using the connected network verify charging session details. 7.2 Cleaning of the cabinet The Terra DC Wallbox Charger is powder coated. This coating must be kept in good condition. Clean the Terra DC Wallbox Charger three times a year in the following way: • Remove rough dirt by spraying with low-pressure tap water. • Apply a neutral or weak alkaline cleaning solution and let it soak. • Remove dirt by hand with a non-woven nylon hand pad. • Rinse thoroughly with tap water. • Do a check on the coating and on the front cover for damage. NOTICE When the Terra DC Wallbox 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 Terra DC Wallbox Charger. If a high-pressure water jet has been used, ensure the inside of the Terra DC Wallbox Charger is dry. • Only use cleaning agents with a pH value between 6 and 8. • Do not use cleaning agents with abrasive components. • Do not use abrasive tools.

2020-12 38/4 4 8 Technical Data 8.1 Electrical data AC Input AC input voltage range (1) 208 - 240 VAC +/- 10% (60Hz) (2) 480 VAC +/- 10% (60Hz) AC input power connection (1) 1-phase, 208-240 VAC: L1, L2, GND (2) 3-phase, 480Y/277 VAC: L1, L2, L3, N, GND Maximum rated input current at nominal voltage (1) 100 A (2) 32 A Recommended upstream overcurrent protection device rating (1) 125 A (2) 40 A Power factor > 0.96 Efficiency 94% at nominal output power DC output Maximum DC output power (1) 19.5 kW @ 208 V (1) 22.5 kW @240 V (2) 24 kW peak; 22.5 kW continuous DC output voltage range CCS1: 150 - 920 VDC CHAdeMO: 150 – 500 VDC Maximum DC output current 60 ADC (1) Single phase configuration (2) Three phase configuration General DC connection standard EN61851-23 / DIN 70121 CCS 2 CHAdeMO 1.0 DC cable length 3.5 meters or 7 meters (12 feet or 23 feet) DC plug type CCS 1 / CHAdeMO RFID data ISO/IEC14443A/B, ISO/IEC15693, NFC reader mode, Mifare, Calypso RFID system FeliCa™1, NFC reader mode Network connection GSM / 4G modem 10/100 Base-T Ethernet

2020-12 39/4 4 8.2 Mechanical data Mechanical data Dimensions (H x W x D) 770 mm x 585 mm x 300 mm / 30.32” x 23.03” x 11.81” Weight 70 kg / 154.32lbs Volume 0,135 m3 Dimensions including packaging (H X W x D) 650 mm x 1200 mm x 800 mm /25.6” x 47.25” x 31.5” Weight including packaging 80 kg / 176.37 lbs. Mechanical impact protection IK10 8.3 Environment Environmental data Ingression protection IP54, NEMA 3S; indoor and outdoor Temperature range – Operation -35°C to + 55°C /-31F to + 131F (derating applies between 45°C and 55°C / 113F-131F) Temperature range - Storage -40 °C to +70 °C / -40F to +158F Humidity 20% - 95% RH - non-condensing Operational noise level 55 dBA @25°C Altitude 2500 m max. 8.4 Certifications EMC: EN 61000-6-4 Class A emission; EN 61000-6-3 Class B emission (pending); EN 61000-6-2 immunity. LVD: IEC 61851-23, IEC 61851-1, IEC 62196, IEC 60950, EN 61010, EN 60335 (see certificates) RFID: ISO/IEC 14443 A/B, ISO/IEC15693, ISO 18902 NFC • UL 2202 • UL 2231 • UL 2231-1 • UL 2231-2 • NEC Article 625 • CSA STD C22.2 No. 107.1 • FCC Part 15 Class A

2020-12 40/4 4 9 Contact information NOTICE In case of problems Please contact your local ABB Service organization or Service partner for first line problem analysis and solving. In case they cannot solve the problem, they will contact the second line Service organization. ABB in your country Please contact ABB in your country for sales, delivery and service information. ABB EV Infrastructure USA ABB Inc. 950 E Elliott Rd Tempe, AZ 85284 Suite 100 United States Phone: 800-435-7365 E-mail: [email protected] ABB EV Infrastructure Canada ABB Inc. 800 Hymus Boulevard Saint-Laurent, QC H4S 0B5 Canada Phone: 800-435-7365 E-mail: [email protected] ABB EV Infrastructure Global Address Delftweg 65 2289 BA Rijswijk The Netherlands Telephone +31 70 307 62 00 Mail [email protected]

2020-12 41/44 10 Appendix A – Mounting points 10.1 Terra DC Wallbox Charger wall mounting

2020-12 42/44 11 Appendix B - Disposal instruction 11.1 Directive on Waste Electrical and Electronic Equipment (WEEE – 2012/19/EU)

2020-12 43/44 12 Appendix C – Pedestal requirements Any pedestal solution designed for Terra DC Wallbox needs to fulfill the specific ISO standards for civil contruc- tions (note: specific local regulations may apply). Additionally, whereas no specific contraint is provided by local regulations, the minimum set of requirements necessary to provide a safe installation are listed in the table below to be verified in the temperature range be- tween -50°C - +60°C: Minimum Wind load resistance 100km/h Minimum compression load capability (applied on center of mass of the WB) 4kN Side / Back / frontal impact MAX (applied on the pedestal/WB) higher point 3kN Pulling /Pushing force applied (to gun holders if they are mechanically con- nected to same stucture and external to the WB area) 3kN Min / Max distance of gun holder from WB (if mechanically connected to pedestal structure) 300mm / 1000mm Rust protection paint Yes Minimum clearance areas side / top / bottom around the charger 300mm Recommended foundation requirements (min tilting torque) To be designed consid- ering the max admitta- ble loads in each direc- tion Vibration test required on the full system According to procedure described in IEC 60068- 2-27: 2008 and IEC 60068-2-6: 2007 Electrical ground connection To the chassis of the DCWB