Alpitronic Hypercharger HYC 150 User manual

hypercharger - Operation Instructions and Installation Guide
Version 2-2
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Operation Instructions and
Installation Guide - Hardware
hypercharger HYC_150 / HYC_300
(75 kW –300 kW)
ultra-fast charging system for electric vehicles
for HW-Versions 4

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Hardware
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Content
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Operation Instructions and
Installation Guide
Version
Version 2-2 of operation instructions and installation guide, February 2021
Original English version
© 2021 alpitronic Srl
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization
by alpitronic Srl. 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 Srl 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 Srl cannot be
held liable for errors in the translation. In case of doubts refer to the Original English version, whose text
is legally binding.
alpitronic Srl 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.
Attention
If the installation instructions described in thisdocument are not adhered
to, any warranty claim will be void.
Manufacturer
alpitronic Srl
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 Srl
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
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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
1-1D
Sep 2018
Ch. Leimegger
Update SW and HW description
1-3A
Jan 2019
A. Oberrauch
Update to hypercharger 3.0
1-3B
April 2019
A. Oberrauch
Wording optimizations
1-4B
January 2020
S. Lucchi
Update to hypercharger V4
February 2020
M. Hofer
Corrections, word optimization, addition of chapter
8
2-1
August 2020
Ch. Leimegger
- Changes and additions suggested by TÜV Süd
February 2021
M. Hofer
- Restructuring of the chapters
- Adding of chapters:
•2.5
•2.6
•4.4
•6
•9
- Extended information in chapter:
•2
•4
•8
•11
•12
- Correction/extension of:
•Figure 1
•Figure 2
•Figure 4
•Figure 6
•Figure 9
•Figure 13
•Figure 14
•Figure 37
•Figure 38
•Figure 40
•Table 1
•Table 5
•Table 6
•Table 11
•Table 12
•Table 13
•Table 14
•Table 17
•Table 26
- Update Declaration of Conformity
- Added Table 21 to conductor cross sections
- Maximum voltage CCS1 set to 600 V
- Cross references
Linguistic and formal revision
2-2
February 2021
M. Hofer
- Linguistic revision
- Adding of:
•Figure 34
- Correction/extension of:
•Figure 3

hypercharger - Operation Instructions and Installation Guide
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•Figure 9
•Table 6
•Table 11
•Table 13
•Table 14
•Table 20
•Table 24
•Table 26
•Table 31

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Content
1.Safety instructions.........................................................................................................12
1.1. Designated use......................................................................................................12
1.2. Users .....................................................................................................................12
1.3. Safety instructions for installation and maintenance...............................................13
2.Product description........................................................................................................15
2.1. Charging interfaces................................................................................................17
2.2. Exterior view ..........................................................................................................21
2.2.1. Nameplate.......................................................................................................23
2.3. Opening of the hypercharger..................................................................................23
2.4. Internal view...........................................................................................................25
2.4.1. HYC_150 internal view....................................................................................25
2.4.2. HYC_300 internal view....................................................................................27
2.5. Main components...................................................................................................29
2.5.1. Power-Stack....................................................................................................29
2.5.2. Input Switchgear .............................................................................................33
2.5.3. Output Switchgear...........................................................................................35
2.5.4. CTRL_COM....................................................................................................39
2.5.5. Display incl. RFID reader ................................................................................41
2.5.6. CTRL_EXT......................................................................................................42
2.6. Additional options...................................................................................................43
2.6.1. Cooling unit.....................................................................................................43
2.6.2. Emergency stop button ...................................................................................44
2.6.2.1. External emergency stop relay.................................................................44
2.6.3. Crash sensors.................................................................................................46
2.6.4. Door contact switches.....................................................................................46
2.6.5. Credit card terminal.........................................................................................46
2.6.6. Barrier-free hypercharger................................................................................47
3.Packaging, transport and storage..................................................................................48
3.1. Packaging..............................................................................................................48
3.2. Transport and storage............................................................................................49
3.3. Unpacking..............................................................................................................51
4.hypercharger installation and commissioning................................................................53
4.1. Mechanical installation of the hypercharger............................................................53
4.1.1. Site configuration ............................................................................................54
4.1.2. Placement of a concrete foundation................................................................56
4.1.3. Mounting the hypercharger base on the foundation.........................................58
4.1.4. Mounting the hypercharger on the base plate .................................................62
4.2. Electrical installation...............................................................................................63
4.2.1. hypercharger schematic HYC_150..................................................................63
4.2.2. hypercharger schematic HYC_300..................................................................64
4.2.3. Preparation mains power-supply cables..........................................................65
4.2.4. Grid Connection..............................................................................................67
4.2.5. Overvoltage protection....................................................................................70

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4.3. Checks before initial startup...................................................................................71
4.4. Commissioning protocol.........................................................................................72
5.Diagnosis and parameterization....................................................................................75
6.Operating the hypercharger...........................................................................................76
6.1. Start charging session............................................................................................76
6.1.1. Authentication.................................................................................................76
6.1.2. Select the charging plug..................................................................................78
6.1.3. Connect the plug.............................................................................................80
6.2. During the charging process...................................................................................81
6.2.1. Charging overview ..........................................................................................81
6.3. Terminate charging session ...................................................................................83
6.3.1. Leaving screen saving mode...........................................................................83
6.3.2. Charging stop..................................................................................................83
6.4. Procedure for error messages................................................................................84
6.4.1. Authorization failed..........................................................................................84
6.4.2. No connector available....................................................................................84
6.4.3. Connector damaged........................................................................................85
6.4.4. Communication error with vehicle....................................................................85
6.4.5. Failed to lock connector ..................................................................................86
6.4.6. The car signalized an error..............................................................................86
6.4.7. Emergency Stop..............................................................................................87
6.4.8. Charging station temporarily unavailable.........................................................87
7.Error description and solution........................................................................................88
8.Maintenance..................................................................................................................89
8.1. Overview of maintenance work ..............................................................................89
8.2. Function test of circuit breaker ...............................................................................90
8.3. Function test of main switch...................................................................................91
8.4. Verification of protective measures.........................................................................91
8.5. Check for cleanliness and condensation................................................................92
8.6. Check charging cable.............................................................................................92
8.7. Check screws.........................................................................................................92
8.8. Check overvoltage protection.................................................................................93
8.9. Connectivity of sim cards .......................................................................................93
8.10. Change filter mats...............................................................................................94
8.11. Check coolant.....................................................................................................95
8.11.1. Check coolant level.........................................................................................95
8.11.2. Check coolant concentration...........................................................................96
8.11.3. Check coolant pH............................................................................................96
8.12. Close the hypercharger.......................................................................................96
9.Repair and service ........................................................................................................97
10. Disposal.................................................................................................................98
11. Technical specifications .........................................................................................99
12. Declaration of Conformity.....................................................................................102

hypercharger - Operation Instructions and Installation Guide
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List of figures
Figure 1: Configuration HYC_150.....................................................................................15
Figure 2: Configuration HYC_300.....................................................................................16
Figure 3: Order of charging points HYC_150 and HYC_300.............................................16
Figure 4: DC-Power characteristic in different configurations............................................19
Figure 5: Cable reach for the two DC outlets of the hypercharger.....................................20
Figure 6: Elements of the charging station HYC_150 and HYC_300.................................21
Figure 7: External dimensions HYC_150 (in mm) .............................................................22
Figure 8: External dimensions HYC_300 (in mm) .............................................................22
Figure 9: Example of nameplate for hypercharger HYC_300............................................23
Figure 10: Half cylinder (data in mm)................................................................................23
Figure 11: Order for opening the hypercharger doors .......................................................24
Figure 12: Locking mechanism for the display door ..........................................................24
Figure 13: Internal view hypercharger HYC_150 (service-, display-, charging cable side) 25
Figure 14: Internal view hypercharger HYC_300 (service-, display- and charging cable-side)
.........................................................................................................................................27
Figure 15: Dimensions of Power-Stack.............................................................................29
Figure 16: AC connection block........................................................................................30
Figure 17: DC connection block........................................................................................30
Figure 18: Status indication of Power-Stack......................................................................31
Figure 19: AC input switchgear of the HYC_150...............................................................33
Figure 20: AC input switchgear of the HYC_300...............................................................34
Figure 21: Input switchgear HYC_300_f with fuses (optional)...........................................35
Figure 22: DC output switchgear of the HYC_150 (bottom view) ......................................35
Figure 23: DC output switchgear of the HYC_150 (top view) ............................................36
Figure 24: DC output switchgear of the HYC_300 (bottom view) ......................................37
Figure 25: DC output switchgear of the HYC_300 (top view) ............................................37
Figure 26: Location of the CTRL_COM in the hypercharger..............................................39
Figure 27: CTRL_COM.....................................................................................................40
Figure 28: Display module................................................................................................41
Figure 29: Location of the CTRL_EXT in the hypercharger...............................................42
Figure 30: Cooling unit for cooled charging cable (optional)..............................................43
Figure 31: Location of the relais in the hypercharger.........................................................44
Figure 32: Connection options external emergency stop...................................................45
Figure 33: Contactless credit card terminal (model COR A20)..........................................46
Figure 34: Barrier-free hypercharger.................................................................................47
Figure 35: Packaging of the hypercharger ........................................................................48
Figure 36: Vertical transport with pallet truck or forklift......................................................49
Figure 37: Crane eyelets on top of the packaging.............................................................50
Figure 38: Unpacking the hypercharger............................................................................52
Figure 39: Relevant components for the mechanical installation of the hypercharger .......53
Figure 40: Recommended distances for site configuration................................................55
Figure 41: hypercharger concrete foundation....................................................................56
Figure 42: Backfill of the foundation..................................................................................57
Figure 43: hypercharger base...........................................................................................58
Figure 44: hypercharger base for the HYC_150 (dimensions in mm)................................58
Figure 45: hypercharger base for the HYC_300 (dimensions in mm)................................59
Figure 46: Position of the HYC_150 (blue) and HYC_300 (red) base on the foundation ...60
Figure 47: Alignment of the base and cable entry plates on the foundation.......................60
Figure 48: Distances between the base and the outer dimensions of the HYC_150 (top view)
.........................................................................................................................................61

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Figure 49: Distances between the base and the outer dimensions of the HYC_300 (top view)
.........................................................................................................................................61
Figure 50: hypercharger schematic for the HYC_150........................................................63
Figure 51: hypercharger schematic for the HYC_300........................................................64
Figure 52: Cable jig, used to prepare mains power supply cables (HYC_150 left and
HYC_300 right).................................................................................................................66
Figure 53: Connecting of the input busbars (HYC_150 left, HYC_300 right) .....................67
Figure 54: Sideview of the input busbars (HYC_150 left, HYC_300 right).........................68
Figure 55: Available installation space in the hypercharger for HYC_300 (1)....................68
Figure 56: Available installation space in the hypercharger for HYC_300 (2)....................69
Figure 57: Authentication..................................................................................................76
Figure 58: Position of RFID reader....................................................................................76
Figure 59: Kiosk Mode......................................................................................................77
Figure 60: Checking ID.....................................................................................................77
Figure 61: Select plug.......................................................................................................78
Figure 62: Buttons for navigation ......................................................................................78
Figure 63: Language selection..........................................................................................79
Figure 64: Plug connection ...............................................................................................80
Figure 65: Charging overview...........................................................................................81
Figure 66: Charge overview with two active charging processes ......................................82
Figure 67: Charging stop ..................................................................................................83
Figure 68: Disconnect Plug...............................................................................................83
Figure 69: Authorization failed ..........................................................................................84
Figure 70: No connector available.....................................................................................84
Figure 71: Connector damaged ........................................................................................85
Figure 72: Communication error .......................................................................................85
Figure 73: Failed to lock connector...................................................................................86
Figure 74: Vehicle Error....................................................................................................86
Figure 75: Emergency Stop ..............................................................................................87
Figure 76: Maintenance ongoing.......................................................................................87
Figure 77: Function test of the circuit breaker...................................................................90
Figure 78: Function test of main switch.............................................................................91
Figure 79: Digital multimeter.............................................................................................91
Figure 80: Check of overvoltage protection.......................................................................93
Figure 81: Compress the sim slot......................................................................................93
Figure 82: Replacement filter mats ...................................................................................94
Figure 83: Checking the cooling liquid level......................................................................95
Figure 84: Check the coolant concentration using a refractometer....................................96

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List of tables
Table 1: Overview DC power and options of the hypercharger product family ..................15
Table 2: Charging interfaces.............................................................................................17
Table 3: Additional charging interfaces for automotive multichargers................................17
Table 4: Possible combinations of charging interfaces......................................................18
Table 5: hypercharger HYC_150 cabinet components......................................................26
Table 6: hypercharger HYC_300 cabinet components......................................................28
Table 7: Technical data.....................................................................................................31
Table 8: Mechanical data..................................................................................................31
Table 9: Electrical data AC connection .............................................................................32
Table 10: Electrical data DC connection ...........................................................................32
Table 11: AC input switchgear components for hypercharger HYC_150...........................33
Table 12: AC input switchgear components for hypercharger HYC_300...........................34
Table 13: DC output switchgear components for hypercharger HYC_150.........................36
Table 14: DC output switchgear components for hypercharger HYC_300.........................38
Table 15: Display properties .............................................................................................41
Table 16: Dimensions of the packaging ............................................................................48
Table 17: Maximum weight and threat size for eyebolts for different hypercharger product
types.................................................................................................................................49
Table 18: Distances..........................................................................................................54
Table 19: Distances between base plate and outer dimensions of charging station..........62
Table 20: Available cable entry plates for hypercharger base...........................................65
Table 21: Recommended conductor cross sections..........................................................69
Table 22: Checks to be carried out before commissioning................................................71
Table 23: Default Charging Station IP address .................................................................75
Table 24: Error description and troubleshooting................................................................88
Table 25: Periodic maintenance work...............................................................................89
Table 26: Technical data...................................................................................................99
Table 27: Mechanical data................................................................................................99
Table 28: Electrical connection for HYC_150....................................................................99
Table 29: Electrical connection for HYC_300..................................................................100
Table 30: Electrical connection for HYC_300_f...............................................................100
Table 31: Standby power consumption...........................................................................101
Table 32: Frequency bands and transmission levels of HYC_150 / HYC_300................101

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1Safety instructions
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1. Safety instructions
This chapter contains the safety instruction which must 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 hypercharger ultra-fast charging system.
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 the AC cable, which needs to be in possess of the user. A
charging cord shall not be altered to extend or divide the cable length.
No adapters may be used which are not explicitly approved by the
vehicle manufacturer.
The use of Y-cables or similar devices is not permitted.
No cable extensions may be used.
National application guidelines and specifications for charging stations
must be taken into account.
1.2. Users
These operation instructions and installation guides are intended for the operators
responsible for installation, operation, service and maintenance of the hypercharger ultra-
fast charging system for electric vehicles. These operators should have an in-depth
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.

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1.3. Safety instructions for installation and maintenance
These warnings and instructions apply to all activities of installation, service and
maintenance on the hypercharger.
Attention
Any disregard from these instructions can lead to serious or fatal
personal injury, as well as serious damage to property.
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 hypercharger may be carried out only
while power is off/disconnected. 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 1000 Vdc) 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 must be properly closed and locked after
installation, service or repair operations.

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1Safety instructions
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Warning of hot surface
Some 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 any task such as disassembly, repair or replacement
of components 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 good when assembling and disassembling components
in order to avoid crushing people or body part.
Remarks
Pushing the (optionally installed) Emergency stop button (see chapter
2.6.2) 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 QB1 (see
Figure 13 and Figure 14) in the cabinet, rotate the handle to position ‘0’.
This will turn off all internal components of the hypercharger.

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2Product description
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2. Product description
The hypercharger product line offers the choice between two different housings, which can
be configured with various options as shown in the following table:
Model
Options
DC-Power
Charging Interfaces
(see chapter 2.1)
HYC_150
- 1 Power-Stack →75 kW
- 2 Power-Stacks →150 kW
- 1 DC charging cable
- 2 DC charging cables
- AC socket with shutter or AC cable
HYC_300
- 1 Power-Stack →75 kW
- 2 Power-Stacks →150 kW
- 3 Power-Stacks →225 kW
- 4 Power-Stacks →300 kW
- 1 DC charging cable
- 2 DC charging cables
- 3 DC charging cables
- AC socket or AC cable
Table 1: Overview DC power and options of the hypercharger product family
Remark
As standard,the hypercharger housing is delivered with the housing colour
“RAL Noir 2100". The reflector strips on the door have the standard colour
“Pantone 3115 C".
The customer can choose any RAL housing color as well as any RAL
reflector strip color as an option. It is also possible to order individual
foiling.
75 kW hypercharger Power-Stacks are used to supply the DC charging cables installed on
the hypercharger with power (detailed information in chapter 2.5.1).
One Power-Stack can supply only one DC charging cable at the same time. The
hypercharger Power-Stacks can be switched in parallel mode to increase the power
conducted via one DC charging cable.
The HYC_150 can be equipped with at least one or a maximum of two Power-Stacks and
with up to a maximum of 2 DC charging cables and a 22 kW AC charging socket or AC
cable:
Figure 1: Configuration HYC_150

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2Product description
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The HYC_300 can be equipped with one, two, three or four Power-Stacks and with up to 3
DC charging cables and a 22 kW AC charging socket or AC cable:
Figure 2: Configuration HYC_300
Remark
The order of the charging points (with view of the charging cable door)
is always from left to right, AC - if available - is in last place.
Figure 3: Order of charging points HYC_150 and HYC_300
Remark
Customs tariff number of the hypercharger: 85044055

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2.1. Charging interfaces
The following charging interfaces can be selected for the hypercharger:
Charging interfaces
Charging interface
Max. Voltage capability [V]
Max. current capability [A]
CCS Combo 2 (not liquid
cooled cable)
1.000V DC
200 A / 250 A /
400 A (500 A Boost) DC
CCS Combo 2 HPC (liquid
cooled cable)
1.000V DC
500 A DC
CHAdeMO (not liquid
cooled cable)
500V DC
125 A DC / 200 A DC
22 kW AC Socket Type 2
(with shutter) or AC cable
400V 3~
32 A AC
Table 2: Charging interfaces
Attention
The total performance of the HYC_150 is limited to a 250 A grid
connection.
The total performance of the HYC_300 is limited to a 500 A grid
connection.
Remark
The usable DC-Power on a DC-outlet is limited by the maximum current of
the used DC-charging cable. The effective current carrying capacity of the
charging interfaces is specified on the nameplate (see chapter 2.2.1).
For the automotive industry also CCS1 and GB/T interfaces are possible:
Charging interfaces
Charging interface
Max. Voltage capability [V]
Max. current capability [A]
CCS 1 US (not liquid cooled
cable)
600 V DC
200 A DC
GB/T China
750 V DC
250 A DC
Table 3: Additional charging interfaces for automotive multichargers
The following charging interfaces can be selected for the hypercharger in various
combinations:
Charging interfaces
Connector 1
Connector 2
Connector 3
Connector 4
HYC_150
CCS Combo 2*
N/A
N/A
CHAdeMO
N/A
N/A
CCS Combo 2*
CCS Combo 2*
N/A
N/A
CCS Combo 2*
CHAdeMO
N/A
N/A

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Charging interfaces
Connector 1
Connector 2
Connector 3
Connector 4
HYC_300
CCS Combo 2*
N/A
CHAdeMO
N/A
CCS Combo 2*
N/A
CCS Combo 2*
CCS Combo 2*
N/A
CHAdeMO
fCCS Combo 2*
N/A
CHAdeMO
CCS Combo 2*
*possibility of cooled cable
Table 4: Possible combinations of charging interfaces
Depending on the configuration of the hypercharger, both DC charging and AC charging are
offered for the vehicle, whereby both charging processes can also take place in parallel. If
the hypercharger is configured with at least two Power-Stacks and two charging cables, two
vehicles can be chargedwith DC at the same time, whereby each vehicle and charging cable
is assigned to a stack. If at least two Power-Stacks are available, more than one Power-
Stack can be assigned to a vehicle.

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The following figure shows the DC-Power characteristic with one, two, three and four
hypercharger Power-Stacks and different cable types:
- 500 A CCS2 HPC liquid cooled cable
- 400 A CCS2 non liquid cooled cable (500 A with boost)
- 250 A not liquid cooled GB/T and CCS2 cable
- 200 A not liquid cooled CCS1, CCS2 and CHAdeMO cable
- 125 A not liquid cooled CHAdeMO cable
Figure 4: DC-Power characteristic in different configurations

hypercharger - Operation Instructions and Installation Guide
Hardware
Version 2-2
Page 20 of 105
2Product description
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization by alpitronic Srl
In its default configuration, the hypercharger comes with a cable length of 3,5 m. The
following figure shows the operating radius (3 m) of the cables for the two DC outlets of the
hypercharger.
Remark
Optionally, longer cable lengths can be ordered (max. 5 m for cooled and
max. 7 m for uncooled cables). Please contact [e-mail].
Figure 5: Cable reach for the two DC outlets of the hypercharger
AUDI / e-tron
TESLA / Model 3
3m3m