Installation manual Terra AC © Copyright 2020 ABB.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners. Copyright ® ABB EV Infrastructure. All rights reserved. 2 BCM.V3Y01.
Contents 1 2 About this document.............................................................................7 1.1 Function of this document................................................................................................. 7 1.2 Target group.......................................................................................................................7 1.3 Revision history............................................................................................................
3 Safety 23 3.1 Liability ...................................................................................................................................... 23 3.2 Required qualifications for the installation engineer ................................................................. 23 3.3 Personal protective equipment.................................................................................................. 23 3.4 General safety instructions ....................................................
9 10 11 Access to parts................................................................................... 40 9.1 Remove the cabinet cover................................................................................................40 9.2 Install the cabinet cover....................................................................................................40 9.3 Remove the maintenance cover.......................................................................................41 9.
11.13.7 EV charge cable specifications......................................................................... 56 11.14 AC output specifications...................................................................................................56 11.14.1 AC output specifications (Europe).....................................................................56 11.14.2 AC output specifications (North America)......................................................... 57 11.
1 About this document 1.1 Function of this document The document is only applicable for this EVSE (Terra AC), including the variants and options listed in section 11.1. The EVSE from here on in the document is referred to as the EVSE. The document gives the information that is necessary to do these tasks: • • Installation Commissioning 1.2 Target group The document is intended for qualified installation engineers. For a description of the required qualifications, refer to section 3.2. 1.
1.9 General symbols and signal words Signal word Description Symbol Danger If you do not obey the instruction, this can cause injury or death. 1.10. If you do not obey the instruction, this can cause injury. Refer to section 1.10. Warning Refer to section Note: It is possible that not all symbols or signal words are present in this document. 8 BCM.V3Y01.
1.10 Special symbols for warnings and dangers Symbol Risk type General risk Hazardous voltage that gives risk of electrocution Risk of pinching or crushing of body parts Rotating parts that can cause a risk of entrapment Note: It is possible that not all symbols are present in this document. 1.
1.
Note: It is possible that not all terms are present in this document. 1.15 Orientation agreements Z Y D B A A B C D BCM.V3Y01.
Description 2 Description 2.1 Short description The EVSE (Terra AC) is an AC charging station that you can use to supply electricity to an EV. The Terra AC offers tailor-made, intelligent and network charging solutions for your company or home. The EVSE can connect to the internet via GSM, WiFi or LAN. 2.2 Intended use The EVSE is intended for the AC charging of EVs. The EVSE is intended for indoor or outdoor use.
Description 2.3 Type plate H A I J K L B C D E M F N G A B C D E F G Brand Barcode with the serial number Barcode with the part number Product Model number MID accuracy class EVSE rating information Address of the manufacturer H I J K L M N CE mark MID mark and Nobody number MID Certificate number MID Software Checksum MID FW Version Ingress protection rating Reference to the manual Note: The data in the illustration is only an example.
Description Type Plate (for North America, Model # Terra AC Wx-P8-xxxxx) 14 BCM.V3Y01.
Description 2.4 Working principle A B C D E F G H 1. 2. 3. 4. 5. LEDs I AC/DC power supply Ethernet J AC input WiFi K Surge protection 3G/4G L Earth(ground) fault protection RFID M AC input metering Bluetooth N AC isolation relay CPU system O Control pilot Isolation P AC output The user initiates a charge session request (black lines). The EVSE verifies the status of the EV (purple lines). The EVSE goes on and AC power goes to the EV (yellow lines). The charge session starts.
Description 2.5 2.5.1 Overview Overview of the system A B C D 16 EVSE AC grid input EV Parking space E F G RFID card or smartphone Structure to install the EVSE on EV charge cable Part Function EVSE Refer to section 2.2. Structure To install the EVSE on and to keep the EVSE in position.
Description 2.5.2 Overview of the EVSE, outside A B C D E Connection for the EV charge cable Openings for the smart meter connections Opening for the Ethernet cable Opening for the AC input cable LED indicators F G H I Cabinet cover Enclosure RFID reader Type plate Part Function Connection for the EV charge cable To connect the EV charge cable Openings Openings for the cables that go into the EVSE LED indicators To show the status of the EVSE and the charge session. Refer to section 2.7.1.
Description 2.5.
Description 2.6 Options 2.6.1 Display 2.6.2 EV charge cable, Type 2 2.6.3 Socket, Type 2 A Socket The socket for an EV charge cable Type 2 is available with or without a shutter. BCM.V3Y01.
Description 2.6.4 EV charge cable, Type 1 (for North America, Model # Terra AC Wx-P8-xxxxx) 2.6.5 3G/4G Communication You can connect to a 3G/4G network. 2.6.6 Load management Load management makes sure that the available capacity of the building or home is not exceeded. A number of devices share a grid connection, that has a maximum capacity. The total power demand of the devices that use the grid connection must not exceed the grid capacity.
Description A B C Error LED Charging LED Cable and car detection, and car authorization LED D Internet connection LED E EVSE on/off LED Table 1: Error LED Status of the LED Status of the EVSE On Error Off No error Table 2: Charging LED Status of the LED Status of the EVSE On EV is fully charged or has stopped charging Off Not charging Flashing Charging Table 3: Cable and car detection, and car authorization LED Status of the LED Status of the EVSE On A car is connected.
Description 2.8 Description of the mobile app for the EVSE Please download the Chargesync APP from Apple Store and Play Store 2.8.1 Overview of the errors If the EVSE detects a problem, the error LED comes on. The mobile app shows the error description. Short description Description Overcurrent There is an overload on the EV side. Overvoltage The voltage input from gird is exceed. Undervoltage The voltage input from gird is insufficient.
3 Safety 3.1 Liability The manufacturer is not liable to the purchaser of the EVSE or to third parties for damages, losses, costs or expenses incurred by the purchaser or third parties if any target group mentioned in the related documents does not obey the rules below: • • • Obey the instructions in the related documents. Refer to section 1.11. Do not misuse or abuse the EVSE. Only make changes to the EVSE, if the manufacturer approves in writing of the changes.
Symbol Description Safety shoes Safety glasses 3.4 General safety instructions • • • This document, the related documents and the warnings included do not replace your responsibility to use your common sense when you do work on the EVSE. Only do the procedures that the related documents show and that you are qualified for. Obey the local rules and the instructions in this manual. If the local rules contradict the instructions in this manual, the local rules will apply.
3.6 3.7 Safety instructions for earthing • This product must be connected to a grounded, metal, permanent wiring system, or an equipment-grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the product. • Make sure that the connections to the EVSE comply with all applicable local rules.
3.9 Safety Instructions (North America, Model # Terra AC Wx-P8-xxxxx) IMPORTANT SAFETY INSTRUCTIONS WARNING: When using electric products, basic precautions should always be followed, including the following. 1. 2. 3. 4. 5. 6. 7. 8. 9. Read all the instructions before using this product. This device should be supervised when used around children. Do not put fingers into the electric vehicle connector.
4 Installation 4.1 General installation procedure Preliminary requirements 1. 2. • All required permits to agree with the local rules are granted. The AC input cable is available. • There is no voltage on the AC input cable during the complete installation procedure. Tools for installation. Refer to section 11.6. Procedure 1. Unpack the EVSE. Refer to section 4.2. 2. Prepare the site. Refer to chapter 5. 3. Remove the cabinet cover. Refer to section 9.1. 4. Do the mechanical installation.
1. The site must be suitable to install the EVSE. Refer to section 5.1. Procedure 1. Make sure that the space and the airflow around the EVSE are sufficient. Refer to section 11.10.3. 2. Make sure that the correct cables are available at the site. • • • AC input cable. Refer to section 11.13. ModBus and RS485 cables. Refer to section 11.13.4. Ethernet cable. Refer to section 11.13.3.
Note: The mounting screws that are included in the delivery are serviceable for a brick wall. If you want to mount the EVSE on a different type of wall, contact your local representative of the manufacturer (ABB EV Infrastructure). 6.3 Install the EVSE on the wall 1. Put the openings (A) over the mounting screws (B). The upper mounting screws support the EVSE. 2. Install the mounting screws (C). For the torque specifications, refer to section 11.16. BCM.V3Y01.
Electrical installation 7 Electrical installation 7.1 General electrical installation procedure Preliminary requirements • Procedure 1. Remove the maintenance cover. Refer to section 9.3. 2. Install the AC input cable. • • Insert the AC input cable. Refer to section 7.2. Connect the AC input cable. Refer to section 7.3. 3. Install the Ethernet cable. • • Insert the Ethernet cable. Refer to section 7.4.1. Connect the Ethernet cable. Refer to section 7.4.2. 4.
Electrical installation 7.3 Connect the AC input cable 7.3.1 Connect the AC input cable (1 phase) for Europe Models Preliminary requirements • Torque screw driver • AC input cable (1 phase) Procedure 1. Loosen the screws (A). 2. Strip the wires. For the specification, refer to section 11.13.1. 3. Insert the cable connector into the terminal block (B). 4. Connect the below wires: 1. Earthing wire (C) 2. Neutral wire (D) 3. AC input wire (E) Refer to section 11.11. 5.
Electrical installation • Torque screw driver • AC input cable (3 phase, TN, TT networks) • Strain relief for the cable Procedure 1. Loosen the screws (A). 2. Insert the cable connector into the terminal block (B). 3. Connect these wires: 1. 2. 3. 4. 5. Earthing wire (C) Neutral wire (D) L1 (E) L2 (F) L3 (G) Refer to section 11.11. 4. Tighten the screws (A) to the correct torque. For the specification, refer to section 11.16. 7.3.
Electrical installation 1. 2. 3. 4. 7.4.2 Remove the membrane (A) from the EVSE. Make a hole in the center of the membrane. Install the membrane. Put the Ethernet cable (B) through the cable inlet hole. Connect the Ethernet cable Preliminary requirements 1. The Ethernet cable is inserted. Refer to section 7.4.1. Procedure 1. Put the RJ45 plug (A) of the Ethernet cable in the Ethernet RJ45 socket (B). 2. Connect the Ethernet cable to a PC, router, or gateway. 7.4.
Electrical installation 7.4.4 Connect the wires for the smart meter communication Connect the smart meter with ModBus RTU over RS485 to the EVSE. Preliminary requirements • Slotted screw driver • Smart meter with ModBus RTU interface • Wire for RS485. Refer to section 11.13.4. Obey the local rules for the correct wire insulation rating. Procedure 1. Remove the plug (A) of the terminal block (B) from the terminal block (B) of the smart meter connection. 2. Connect the wires: a.
Electrical installation 7.5 Replace the EV charge cable Preliminary requirements 1. • EV charge cable might be determined to be defective (refer to Troubleshooting section or customer service). The replacement of the EV charge cable must be done by an official electrician • EV charge cable within the specifications. Refer to section 11.13. Torque screw driver Procedure for EU Models 1. Get access to the EV charge cable connection: a. Remove the cabinet cover. Refer to section 9.1. b.
Electrical installation Procedure (North America, Model # Terra AC Wx-P8-xxxxx) 7. Get access to the EV charge cable connection: a. Remove the cabinet cover. Refer to section 9.1. b. Remove the maintenance cover. Refer to section 9.3. c. Remove the plastic cover. 8. Disconnect the EV charger 2-pin connector (A) that is receptacle to the CP/CC connector. 9. Loosen the screws (B) on the terminal block output connector (C). 10. Disconnect the wires: • L1(D) • L2 (E) • Earthing wire (G) 11.
8 Commissioning This commissioning is only applicable for single Terra AC use case scenario by using Chargersync APP. For other scenarios (Chargersync Web Portal, OCPP) please contact sales support. 8.1 General commissioning procedure 1. 2. 3. 4. Energize the EVSE. Refer to section 8.2. Set up the EVSE. Refer to section 8.3. Connect the EVSE with the mobile app. Refer to section 8.4. Add a RFID card to the mobile app. Refer to section 8.5. 8.2 Energize the EVSE 1.
8.4 Connect the EVSE with the mobile app Preliminary requirements • Mobile device with the mobile app Procedure 1. Find your pin code in the package with the RFID card. • • The pin code has 8 characters. The letters are case-sensitive. 2. Download the ChargerSync App from the Play Store or App Store. 3. Start the mobile app. 4. Do the instructions that the mobile app shows. 8.5 Add an RFID card to the mobile app Preliminary requirements • RFID card • Mobile device with the mobile app Procedure 1.
9 Access to parts 9.1 Remove the cabinet cover 1. Remove these parts: • • 9.2 Screws (A) Cabinet cover (B) Install the cabinet cover 1. Install these parts: • • BCM.V3Y01.
9.3 Remove the maintenance cover 1. Remove these parts: • • 9.4 Screws (A) Maintenance cover (B) Install the maintenance cover 1. Install these parts: • • 40 Maintenance cover (A) Screws (B) BCM.V3Y01.
10 Troubleshooting 10.1 Troubleshooting procedure 1. Try to find a solution for the problem with the aid of the information in this document. 2. If you cannot find a solution for the problem, contact your local representative of the manufacturer. Refer to section 1.12. 10.2 Troubleshooting table Problem Possible cause Possible solution The current is too high There is an overload on the EV side 1. Examine the EV charge cable connection. 2. Connect the EV charge cable correctly.
Problem Possible cause There is a relay con- The relay contact is overtact failure heated or defective. Cable Mismatch There is no internet connection 1. Examine the relay contact. 2. If necessary, adjust the current. 3. If necessary, replace the relay contact. The rated current capacity Connect a cable that has the same of the cable is different from rated current as the EVSE. the rated current of the Refer to section 11.11. EVSE.
Problem Possible cause The EV charge cable is not connected correctly. Possible solution 1. Examine the connection of the EV charge cable. 2. If necessary, connect the EV charge cable. There is a problem with the mobile app or the RFID card. 1. Make sure that you have 2. registered in the mobile app. Make sure that you use a RFID card that the manufacturer provided. 3. Make sure that the RFID card is added on the mobile app. 4. Start the mobile app. 5. Start the authorization process. 10.
11 Technical data 11.1 EVSE Type The EVSE type is a code. The code is has 10 parts: A1 - A10. Code part Description Value Meaning of the value A1 Brand name Terra AC - A2 Type W Wallbox C Column 4 3.
Technical data Example Terra AC W7-P8-RD-MCD-0 11.2 • • • • A1 = Brand name = Terra AC A2 = Type = Wallbox A3 = 7, Power output = 7.4 kW A4 = Cable type, cable = type 1 • A5 = 8 meters • A6 = authorization = RFID enabled • A7 = Ethernet = double • A8 = metering = applicable • A9 = SIM slot = applicable • A10 = display = applicable • The '0' is an empty field. Mass EVSE type Weight [kg] Terra AC wallbox type 2 with socket (Europe) 3.0 Terra AC wallbox type 2 with an EV charge 7.
Upstream residual-current device (RCD) Minimum Type A, with a rated residual operation current of maximum 30 mA Note: Internal to EVSE is DC fault current monitoring > 6mA 11.3.
Technical data 11.5 General specifications Parameter Specification Compliance and safety • • • • • IEC/EN 61851-1 IEC/EN 62311 IEC/UL 62479 IEC/UL 62955 TüV listed conforming to UL 2594, UL 2231-1, UL 2231-2, UL 1998 CSA C22.2. NO.280 Certification CE, MID, TüV, Energy Star IP or NEMA rating The type plate shows the specification. Refer to section 2.3.
Required tools for installation 11.6 Parameter Specifications Hammer - Spirit level - Drill - Torque screw driver, cross - Torque screw driver, slotted For terminal blocks and plugs with 5 mm pitch Ambient conditions 11.7 11.
Technical data 11.9 Noise level Parameter Specification Noise level Maximum 35 dB(A) 11.10 Dimensions 11.10.1 AC input with socket, cable Type 2 X Y1 Y2 Width of the EVSE Depth of the EVSE Depth of the socket Z1 Z2 Height of the EVSE Distance from the bottom of the EVSE to the center of the socket. Parameter Value [mm] X 195 Y1 110 Y2 33 Z1 320 Z2 70 BCM.V3Y01.
11.10.2 AC input with EV charge cable X Width of the EVSE Y Depth of the EVSE 11.10.3 Z Height of the EVSE Parameter Value [mm] X 195 Y 110 Z 320 Space requirements for installation Z1 A Z2 A 50 EVSE BCM.V3Y01.
11.11 11.11.
11.11.3 230 VAC 1-phase (Europe) U1 L1 U1 11.11.4 N 230 VAC, maximum 264 VAC 240 VAC (for North America, Model # Terra AC Wx-P8-xxxxx) U1 240 VAC, maximum 264 VAC 11.11.5 52 AC input specifications (Europe) Parameter Specification Input AC power connection 1 phase or 3 phase Input voltage (1 phase) 230 VAC Input voltage (3 phase) 400 VAC Standby power consumption 4.6 W Earth (ground) fault protection 30mA AC, 6 mA DC Maximum Input power (1 phase) 3.7kW (16A) or 7.
Technical data 11.11.6 11.12 AC input specifications (North America) Parameter Specification Input AC power connection 240 V AC Standby power consumption 3.6 W Earth (ground) fault protection internal 20 mA AC CCID General logic interface specifications Parameter Specification Connectivity Mobile communication with Nano-SIM socket • • 11.
Cable shielding (optional) Diameter of the phase conductors Diameter of the PE conductor • • 11.13.2 The local rules require shielded cables. The cable shielding must be connected to the PE rail at the two ends of the cable. Refer to the local rules. The same as the diameter of the phase conductors Consult your local electrical codes for the correct wire size, based on the environment, the conductor type and the rating of the EVSE. The wire cross-sectional area is based on the copper wire type.
Technical data Parameter Specification Connector type for the EV charging station Terminal block plug and screws Conductor type Twisted pair, shielded cable (recommended) Conductor size for the terminal block plug (allowed) Europe (IEC) cross-sectional area: 2.5 mm2 to 0.5 mm2 North America (UL): 12 AWG to 30 AWG Conductor size for the terminal block plug (recommended) Minimum 24 AWG (0.
Parameter Specifications EVSE connector type Terminal block plug and screws Wire size for the terminal block plug (allowed maximum) • 2.5 - 0.5 mm2 (Europe) • 12 - 30 AWG (North America) Wire size for the terminal block plug (recommended) 20 AWG (0.75 mm2) minimum Required torque 0.
Technical data 11.15 11.16 AC output voltage range 110 - 240V AC (1 phase) Connection standard Type 1 cable according to SAE J1772 Specific power consumption specifications Power consumption during normal operation Specification [W] Charging Mode 1 Phase 7 Charging Mode 3 Phase 10 Torque specifications Parameter Specification [Nm][(lb.in.)] Terminal block for the AC input 1.2 (10.6) Terminal block for the communication wires 0.5 (4.
12 Display Instructions Scope This document clarifies the display layout of Terra AC wallbox in JUNO project, which is for compliance of MID and all values on this screen will be strictly qualified for measurements verified requirements of MID. 58 BCM.V3Y01.
Technical data Introduction Booting This screen shows the brand information as a loading page when the charger is booting. Standby/Idle This screen shows when the charger is in an idle status which means the charger is available for charging. Position of title Date Guide Total Energy Delivered Serial Number Software Version BCM.V3Y01.
Authorization Case 1. This screen shows when the connector plugged in but the charging is not authorized. Case 2. This screen shows when the charging is authorized but the connector is not plug in. 60 BCM.V3Y01.
Technical data Charging preparing This screen will be displayed when the charger is preparing to charge, which means the charging process is initializing. BCM.V3Y01.
Charging Case1 .This screen will be displayed when a single-phase charger is charging. Real-time voltage and current Real-time power Energy delivered and duration of this charging process Multi-phase Current and voltage will alternate display 3 phases. Real-time voltage and current per phase. 62 BCM.V3Y01.
Technical data Charging completed Start Time Energy delivered and duration of this charging process. BCM.V3Y01.
Fault detected Faults will be displayed respectively according to the different types. 64 BCM.V3Y01.
