Alpitronic Hypercharger HYC 075 User manual

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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Operation Instructions and
Installation Guide
hypercharger 75kW –300kW
(HYC_075 / HYC_150 / HYC_225 / HYC_300)
ultra-fast charging system for electric vehicles
for HW-Versions 2.x

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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hypercharger - Operation Instructions and Installation Guide
Version 1-1C
Content
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization by alpitronic s.r.l.
Operation Instructions and
Installation Guide
Version
Version 1-1C of operation instructions and installation guide, 13th June 2018
Original English version
© 2018 alpitronic S.r.l.
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization
by alpitronic S.r.l.. The information in this document is subject to change without notice.
Although the content of this release was carefully checked for accuracy, errors cannot be entirely ruled
out. If you discover an error, please notify us at [e-mail] . alpitronic S.r.l. assumes no
responsibility for any errors that may appear in this document. This document is originally written in
English. Other language versions are a translation of the original document and alpitronic S.r.l. cannot
be held liable for errors in the translation.
alpitronic S.r.l. shall in no event be liable for any direct, indirect, special, incidental or consequential
loss or damages or damages of any other kind (including, without limitation damages for lost profit or
loss of data) arising out of the use of this document.
Manufacturer
alpitronic S.r.l.
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-Mail: [email protected]
Service
alpitronic S.r.l.
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-Mail: [email protected]

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
Content
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Version History
Version
Date
Author
Description
1-1A
March 2018
P. Senoner
First version
1-1B
May 2018
Ch. Leimegger
Revision and extension to HY_225 and HY_300
1-1C
June 2018
Ch. Leimegger
Correction and extension

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
Content
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Content
1.Safety instructions...........................................................................................................1
1.1. Designated use....................................................................................................... 1
1.2. Users ...................................................................................................................... 1
1.3. Safety instructions for installation and maintenance................................................ 1
1.4. Nameplate............................................................................................................... 4
2.Transport, storage, unpacking and handling....................................................................5
2.1. Packaging............................................................................................................... 5
2.2. Transport, handling and storage.............................................................................. 5
2.3. Unpacking............................................................................................................... 8
3.Product description........................................................................................................10
3.1. Exterior view ..........................................................................................................10
3.2. Site Configuration...................................................................................................11
3.3. Cable reach............................................................................................................12
3.4. Opening of the hypercharger..................................................................................13
3.5. Internal view...........................................................................................................14
3.5.1. HYC_075 and HYC_150 internal view.............................................................14
3.5.2. HYC_225 and HYC_300 internal view.............................................................18
3.6. Hypercharger configurations ..................................................................................22
3.6.1. HYC_075 configuration...................................................................................22
3.6.2. HYC_150 configuration...................................................................................23
3.6.3. HYC_225 configuration...................................................................................24
3.6.4. HYC_300 configuration...................................................................................24
4.Mechanical installation ..................................................................................................26
4.1. Concrete foundation...............................................................................................27
4.2. Adaptor ..................................................................................................................28
4.3. hypercharger-base.................................................................................................28
4.4. Mechanical installation of the hypercharger............................................................30
5.Electrical installation......................................................................................................31
5.1. hypercharger schematic for the HYC_075 and the HYC_150.................................31
5.2. hypercharger schematic for the HYC_225 and the HYC_300.................................32
5.3. Preparation mains power-supply cables.................................................................33
5.4. Grid Connection.....................................................................................................34
5.5. Checks before initial startup...................................................................................35
6.Diagnosis and parameterization....................................................................................36
6.1. User interface.........................................................................................................36
6.2. Diagnosis...............................................................................................................39
6.3. Parameterization....................................................................................................42
7.Error description and removal .......................................................................................47
8.Maintenance..................................................................................................................48
8.1. Overview of maintenance work ..............................................................................48
8.2. Replacing a hypercharger power-stack ..................................................................49
8.3. Cooling unit for cooled charging cable (optional)....................................................50
9.Technical specifications.................................................................................................52
10. Declaration of Conformity.......................................................................................54

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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List of figures
Figure 1: Example of Nameplate for hypercharger............................................................. 4
Figure 2: Vertical and horizontal transport with pallet truck or forklift.................................. 6
Figure 3: Crane eyelets on top of the packaging................................................................ 6
Figure 4: Unpacking the hypercharger............................................................................... 9
Figure 5: Elements of the charging station........................................................................10
Figure 6: Recommended distances for site configuration..................................................11
Figure 7: Cable reach for the two DC outlets of the hypercharger.....................................12
Figure 8: Order for opening the hypercharger...................................................................13
Figure 9: Internal view hypercharger HYC_075 and HYC_150 (left, front and right)..........14
Figure 10: DC output switchgear of the HYC_075 and the HYC_150................................16
Figure 11: AC input switchgear of the HYC_075 and the HYC_150..................................17
Figure 12: Internal view hypercharger HYC_225 and HYC_300 (left, front and right)........18
Figure 13: DC output switchgear of the HYC_225 and the HYC_300 (bottom view) .........19
Figure 14: DC output switchgear of the HYC_225 and the HYC_300 (top view) ...............20
Figure 15: AC input switchgear of the HYC_225 and the HYC_300..................................21
Figure 16: hypercharger configurations and options .........................................................22
Figure 17: DC output power of the 75kW hypercharger ....................................................23
Figure 18: DC output power of the 150kW hypercharger, whole DC-power on one outlet.23
Figure 19: DC output power of the 225kW hypercharger ..................................................24
Figure 20: DC output power of the 300kW hypercharger, whole DC-power on one outlet.25
Figure 21: Naming of relevant components for the mechanical installation of the
hypercharger ....................................................................................................................26
Figure 22: Distances between base plate and outer dimensions of charging station on the
concrete foundation (HYC_075, HYC_150) (front/top view)..............................................27
Figure 23: Distances between base plate and outer dimensions of charging station on the
concrete foundation (HYC_225, HYC_300) (front/top view)..............................................28
Figure 24: hypercharger-base for the HYC_075 and HYC_150 (front/top view left) ..........29
Figure 25: hypercharger-base for the HYC_225 and HYC_300 (front/top view left) ..........29
Figure 26: hypercharger schematic for the HYC_075 and the HYC_150...........................31
Figure 27: hypercharger schematic for the HYC_225 and the HYC_300...........................32
Figure 28: Cable inlet and connection lengths for HYC_075 to HYC_300.........................33
Figure 29: Connecting of the input Busbars (HYC_075/150 left, HYC_225/300 right).......34
Figure 30: Credentials form shown at first connection with web interface..........................36
Figure 31: Home screen of web interface..........................................................................37
Figure 32: Example of SIM Signal webpage .....................................................................39
Figure 33: Example of Process View webpage.................................................................40
Figure 34: Example of Stop Button webpage....................................................................41
Figure 35: Example of BOOT Configuration webpage.......................................................42
Figure 36: Example of OCPP Configuration webpage.......................................................43
Figure 37: Example of GUI Configuration webpage..........................................................44
Figure 38: Example of Ethernet Configuration webpage...................................................45
Figure 39: Example of SIM Configuration webpage..........................................................46
Figure 40: Example of the Password Configuration webpage...........................................46
Figure 41: Replacing a Power-Stack.................................................................................49
Figure 42: Cooling unit for cooled charging cable (option) ................................................50

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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List of tables
Table 1: Dimension of the packaging................................................................................. 5
Table 2: Maximum weight and threat size for eyebolts for the whole hypercharger product
range................................................................................................................................. 7
Table 3: Distances to keep free for service.......................................................................12
Table 4: hypercharger HYC_075 and HYC_150 cabinet components...............................15
Table 5: DC output switchgear components for hypercharger HYC_075 and HYC_150 ...17
Table 6: AC input switchgear components for hypercharger HYC_075 and HYC_150......17
Table 7: hypercharger HYC_225 and HYC_300 cabinet components...............................19
Table 8: DC output switchgear components for hypercharger HYC_225 and HYC_300 ...20
Table 9: AC input switchgear components for hypercharger HYC_225 and HYC_300......21
Table 10: Distances between base plate and outer dimensions of charging station..........27
Table 11: Available cable entry adaptor plates for hypercharger-base (not available yet).33
Table 12: Checks to be carried out before commissioning................................................35
Table 13: Default Charging Station IP address .................................................................36
Table 14: Default Credentials to web interface..................................................................36
Table 15: Error description and troubleshooting................................................................47
Table 16: Periodic maintenance work...............................................................................48
Table 17: Relation frost protection to dilution ratio ............................................................51
Table 18: Technical data (general)....................................................................................52
Table 19: Mechanical data................................................................................................52
Table 20: Electrical connection for HYC_075....................................................................52
Table 21: Electrical connection for HYC_150....................................................................53
Table 22: Electrical connection for HYC_225....................................................................53
Table 23: Electrical connection for HYC_300....................................................................53

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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hypercharger - Operation Instructions and Installation Guide
Version 1-1C
1Safety instructions
Page 1 of 57
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1. Safety instructions
This chapter contains the safety instruction which have to be considered at installation,
operation and maintenance of the hypercharger ultra-fast charging system for electric
vehicles. Incorrect operation as a result of non-compliance with the operation instructions
may lead to severe injuries or damages. This safety operation must be read carefully
before the installation, operation and maintenance of the test bench.
1.1. Designated use
The hypercharger ultra-fast charging system for electric vehicles is intended to be used
both in indoor and outdoor environments for performing ultra-fast charging for electric
vehicles.
Attention
The charging station is designed for a stationary installation in an
ambient with pollution degree class 3.
For the connection between the electric vehicle supply equipment
(EVSE) and electric vehicle (EV), no additional cables are required
besides from the one provided with the hypercharger. A charging cord
should not be altered to extend or divide the cable range.
No adapters may be used which are not approved by the vehicle
manufacturer.
Depending on a socket or vehicle coupling the hypercharger may only
changer a single vehicle. Y-cables or similar are not allowed.
1.2. Users
These operation instructions and installation guide are intended for persons who are
responsible to install, operate, service and maintain the hypercharger ultra-fast charging
system for electric vehicles. These persons should have at least a basic knowledge of
electrical high power systems and electric vehicles. Prior to carrying out any work the
operator and the responsible technical personnel must carefully read these instructions.
1.3. Safety instructions for installation and maintenance
This warnings and instructions apply to all activities of installation, service and
maintenance on the hypercharger.
Disregards from these instructions can lead to serious or fatal personal
injury, as well as serious damage to property.

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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1Safety instructions
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Attention
Installation and maintenance of the hypercharger ultra-fast charging
system for electric vehicles must only be carried out by qualified
personnel.
Before putting the system into operation, check the correct state of the
installation and all connections.
Electrostatic discharge
The control cabinet contains components and circuit boards that are
sensitive to electrostatic discharge. During assembly and
maintenance, sufficient ESD measures should be taken to protect the
electronic components (for example, wearing a grounding wristband).
Warnings
Warning of hazardous electrical voltage
Installation and maintenance of the test bench must be carried out only
when power is removed. Before performing any installation, disassembly,
repair or replacement of components, switch off the external group switch
and the main switch in the hypercharger cabinet and do a voltage check
to make sure that the electrical power is disconnected from the system.
Inside the hypercharger cabinet, hazardous electrical voltages are
present (up to 1000Vdc) even if all circuit breakers are switched off, do
not allow unqualified persons to go near it.
Only hypercharger certified technicians are permitted to install,
disassembly, repair or replace components on the hypercharger. The
hypercharger cabinet doors has to be locked after installation, service or
repair operations.
Warning of hot surface
Some cabinet internal components of the hypercharger like power stack
housings, cooling system, and conductors can remain hot long after the
power supply has been disconnected.
Prior to performing disassembly, repair or replacement of components
activities make sure that all components have cooled down.
Heavy weight
Please note that the individual components of the device can be very
heavy, for example the power-stacks.
Crushing
Please take care when assembling and disassembling components that
they do not squeeze a human body or body part.

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
1Safety instructions
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Hints
Pushing the (optionally installed) Stop button (see Fehler!
Verweisquelle konnte nicht gefunden werden.) on the front door stops
charging/disables charging. The hypercharger power stacks will be
turned off.
To turn off the hypercharger, one can find the main switch (see Figure
26) in the cabinet, rotate the handle to position ‘0’. This will turn off all the
main components of the hypercharger.

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
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1Safety instructions
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1.4. Nameplate
Depending on the configuration of the charging station, the following nameplate (example)
may be located on the device.
Modell: HYC_075 / HYC_150
Manufactured: 04/2018
Main voltage: 3x 400 (±10%)
Frequency: 50 (±5%)
Maximal input current: 250
Degree of protection: IP54
Charging voltage range: 150…1000
Max. Weight: 400
Mady in Italy by
alpitronic GmbH
Bozner Boden Mitterweg 33
I-39100 Bozen
SERIAL NR: 18BZ00001
Vac
Hz
A
Vdc
kg
HW-Revision: 2.0
Figure 1: Example of Nameplate for hypercharger

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
2Transport, storage, unpacking and handling
Page 5 of 57
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2. Transport, storage, unpacking and handling
2.1. Packaging
The hypercharger is delivered in a specialized wood packaging. The following figure shows
the packaging, and size information for the two charger types.
Type
W [mm]
D [mm]
H [mm]
HYC_075, HYC_150
1200
800
2340
HYC_225, HYC_300
1200
1120
2340
Table 1: Dimension of the packaging
2.2. Transport, handling and storage
In its wood packaging, the hypercharger can be transported vertically as well as
horizontally, this allows flexibility in transportation. It can be transported in ordinary trucks
as well as in vans (horizontal position during transport).
W
H
D

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Version 1-1C
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2Transport, storage, unpacking and handling
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Figure 2: Vertical and horizontal transport with pallet truck or forklift
In addition to the transport with a pallet truck or a forklift, the hypercharger can also be
moved using the two crane eyelets which are on top of the packaging.
Figure 3: Crane eyelets on top of the packaging

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
2Transport, storage, unpacking and handling
Page 7 of 57
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Attention
The hypercharger must be stored in its original packaging in a dry
environment from -40°C to +55°C.
The following table contains the weight indication for the single hypercharger types:
Type
Weight
hypercharger [kg]
Weight
packaging [kg]
Threat size
for eyebolts
HYC_075
300
140
M12
HYC_150
400
140
M12
HYC_225
550
160
M12
HYC_300
650
160
M12
Table 2: Maximum weight and threat size for eyebolts for the whole hypercharger product range

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Version 1-1C
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2Transport, storage, unpacking and handling
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2.3. Unpacking
It is recommended to transport the hypercharger to its final destination in its original
packaging and unpack it there. The following illustrations show the sequence to unpack
the hypercharger:
Unpacking the hypercharger
1
2
3
4
5
Remove the
hypercharger-base
Remove bands
Lift top cover
Remove
screws on
rear panel
Remove rear panel
6
7
8
9
10
Remove side
panels
Remove screws
between panel
and pallet
Remove rear panel
Open left
side door
Remove screws on
the base plate of the
hypercharger

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
2Transport, storage, unpacking and handling
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11
12
13
14
15
Open right side
door
Open front door
Remove front acrylic
glass cover
Remove
screws on the
base plate of
the
hypercharger
Close all doors, lift
the hypercharger
with a crane and
remove the pallet
Figure 4: Unpacking the hypercharger
The outer packaging is made of 100% recyclable wood, the inner packaging is made of
plastic and must be disposed separately.

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Version 1-1C
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3Product description
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3. Product description
The HYC_075 and the HYC_150 of the hypercharger product family have the same
housing and in the case of the HYC_075 the housing is equipped with one 75kW
hypercharger power stack. The HYC_150 is equipped with two hypercharger power stacks
(each 75kW) and has a nominal power of 150kW.
The HYC_225 and the HYC_300 of the hypercharger product family have the same but
larger housing and in the case of the HYC_225 the housing is equipped with three 75kW
hypercharger power stack. The HYC_300 is equipped with four hypercharger power stacks
(each 75kW) and has a nominal power of 300kW.
3.1. Exterior view
The following figure shows the different connections of the device from the outside.
Figure 5: Elements of the charging station
A DC charge outlet 1
B DC charge outlet 2 (optional)
C AC charge socket (optional)

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
3Product description
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D air outlet
E air inlet
F Stop button (optional)
G Display / HMI
H RFID card reader
I GSM / LTE / WLAN antenna
J door handle
3.2. Site Configuration
When installing the hypercharger, it must be ensured to give certain a minimum distance
from possible objects around the hypercharger, to allow adequate airflow, and secondly,
space for possible service or maintenance operations.
Attention
A mechanical ramming protection with sufficient stability should be
provided to protect the charging station.
The following figure shows the recommended minimum distances which should be kept
free during installation on site:
Figure 6: Recommended distances for site configuration
The figure above shows the hypercharger housing for the HYC_075 and the HYC_150, the
distances for the HYC_225 and the HYC_300 can be found in the following table.

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Version 1-1C
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3Product description
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Type
W1 [mm]
D1 [mm]
D2 [mm]
D3[mm]
L [mm]
HYC_075, HYC_150
854
1100
350
1000
420
HYC_225, HYC_300
854
1100
350
1000
732
Table 3: Distances to keep free for service
Attention
The legal minimum widths for escape routes must be respected in any
case.
To allow easy replacement of the power-stacks, a clearance of at least 110cm must be
available on the left side (see D1).
At least a distance of 1100mm (D1) and 1000mm (D3) must be maintained in front of the
ventilation grilles to not impair the circulation of the supply and exhaust air. It must also be
prevented that the exhaust air is reintroduced into the supply air circuit.
Impairments to the air circulation may lead to a reduced efficiency of the charging station.
3.3. Cable reach
In its default configuration, the hypercharger comes with a cable length of 350cm. The
following figure shows the operating radius (3m) of the cables for the two DC outlets of the
hypercharger.
Figure 7: Cable reach for the two DC outlets of the hypercharger