Juice ULTRA User manual

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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
JUICE ULTRA (75kW –300kW)
ultra-fast charging system for electric vehicles
Version 1-3A | 3.0
IMPORTANT:
Read this manual before you start using the device!
Failure to comply with these instructions may result in injury or death, damage
to the device and harm to the environment.
Keep the manual in a safe place for future reference.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
Content
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization by alpitronic s.r.l.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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 1-3A of operation instructions and installation guide, 25th January 2019
Original English version
© 2019 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 i[email protected] . 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.
Attention
If the installation instructions described in this documentare not adhered
to, any warranty claim will be void.
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: [e-mail]

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
Content
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization by alpitronic s.r.l.
Content
1.Safety instructions...........................................................................................................7
1.1. Designated use....................................................................................................... 7
1.2. Users ...................................................................................................................... 7
1.3. Safety instructions for installation and maintenance................................................ 7
2.Product description........................................................................................................10
2.1. Additional Options..................................................................................................13
2.1.1. Barrier-free JUICE ULTRA..............................................................................13
2.1.2. Emergency stop button ...................................................................................13
2.1.3. Door contact switches.....................................................................................13
2.1.4. JUICE ULTRA colors.......................................................................................13
2.2. DC-Power ..............................................................................................................14
2.3. Charging interfaces................................................................................................15
2.4. Nameplate..............................................................................................................16
2.5. Exterior view ..........................................................................................................16
2.6. Opening of the JUICE ULTRA................................................................................16
2.7. Internal view...........................................................................................................20
2.7.1. double slot version internal view......................................................................20
2.7.2. quadruple slot version internal view.................................................................24
3.Transport, storage, unpacking and handling..................................................................29
3.1. Packaging..............................................................................................................29
3.2. Transport, handling and storage.............................................................................30
3.3. Unpacking..............................................................................................................31
4.JUICE ULTRA installation .............................................................................................33
4.1. JUICE ULTRA mechanical installation ...................................................................34
4.1.1. Relevant components for JUICE ULTRA installation.......................................34
4.1.2. Cable reach.....................................................................................................35
4.1.3. Site configuration ............................................................................................36
4.1.4. JUICE ULTRA base positioning ......................................................................38
4.1.5. JUICE ULTRA base........................................................................................40
4.2. Electrical installation...............................................................................................42
4.2.1. JUICE ULTRA schematic for the double slot version.......................................42
4.2.2. JUICE ULTRA schematic for the quadruple slot version..................................43
4.2.3. Preparation mains power-supply cables..........................................................44
4.2.4. Grid Connection..............................................................................................45
4.2.5. Checks before initial startup............................................................................47
5.Diagnosis and parameterization....................................................................................48
5.1. User interface.........................................................................................................48
5.2. Diagnosis...............................................................................................................51
5.3. Parameterization....................................................................................................56
6.Error description and removal .......................................................................................65
7.Maintenance..................................................................................................................66
7.1. Overview of maintenance work ..............................................................................66
7.2. Replacing a JUICE ULTRA power-stack ................................................................67
7.3. Cooling unit for cooled charging cable (optional)....................................................68

JUICE ULTRA - Operation Instructions and Installation Guide
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8.Technical specifications.................................................................................................69
9.Declaration of Conformity..............................................................................................70
List of figures
Figure 1: double slot version with one (left) and two (right) power-stacks..........................11
Figure 2: double slot version with two DC charging cables and one AC socket.................11
Figure 3: quadruple slot version with one, two, three and four power-stacks.....................12
Figure 4: quadruple slot version with four DC charging cables and one AC socket...........12
Figure 5: Standard JUICE ULTRA and barrier-free version...............................................13
Figure 6: DC-Power characteristic with one, two, three and four JUICE ULTRA power-stacks
and different cable types...................................................................................................14
Figure 7: Example of nameplate for JUICE ULTRA .............................................................
Figure 8: Elements of the charging station........................................................................16
Figure 9: Order for opening the JUICE ULTRA doors .......................................................18
Figure 10: Locking mechanism for the display door ..........................................................19
Figure 11: Internal view JUICE ULTRA double slot version (service-, display-, charging cable
- side) ...............................................................................................................................20
Figure 12: DC output switchgear of the double slot version (bottom view) ........................22
Figure 13: DC output switchgear of the double slot version (top view)..............................22
Figure 14: AC input switchgear of the double slot version.................................................23
Figure 15: Internal view JUICE ULTRA quadruple slot version (service-, display- and
charging-cable-side).........................................................................................................24
Figure 16: DC output switchgear of the quadruple slot version (bottom view)...................26
Figure 17: DC output switchgear of the quadruple slot version (top view).........................26
Figure 18: AC input switchgear of the quadruple slot version............................................27
Figure 19: Vertical transport with pallet truck or forklift......................................................30
Figure 20: Crane eyelets on top of the packaging.............................................................30
Figure 21: Unpacking the JUICE ULTRA..........................................................................32
Figure 22: Relevant components for the mechanical installation of the JUICE ULTRA.....34
Figure 23: Cable reach for the two DC outlets of the JUICE ULTRA.................................35
Figure 24: Recommended distances for site configuration................................................37
Figure 25: Distances between base plate and outer dimensions of charging station on the
concrete foundation double slot version (display/top view)................................................38
Figure 26: Distances between base plate and outer dimensions of charging station on the
concrete foundation quadruple slot version (display/top view)...........................................39
Figure 27: JUICE ULTRA-base for the double slot version................................................40
Figure 28: JUICE ULTRA-base for the quadruple slot version ..........................................40
Figure 29: JUICE ULTRA schematic for the double slot version .......................................42
Figure 30: JUICE ULTRA schematic for the quadruple slot version ..................................43
Figure 31: Cable inlet and connection lengths for double slot version and quadruple slot
version..............................................................................................................................44
Figure 32: Connecting of the input Busbars (double slot version left, quadruple slot version
right).................................................................................................................................45
Figure 33: Sideview of the input Busbars (double slot version left, quadruple slot version
right).................................................................................................................................46
Figure 34: Credentials form shown at first connection with web interface..........................48
Figure 35: Home screen of web interface..........................................................................49
Figure 36: Example of SIM Signal webpage .....................................................................51
Figure 37: Example of Process View webpage.................................................................52
Figure 38: Example of Stop Button webpage....................................................................53
Figure 39: Example of connector cycles webpage............................................................53

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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Figure 40: Example of the Stack webpage........................................................................54
Figure 41: Example of the Software Version webpage......................................................55
Figure 42: Example of BOOT Configuration webpage.......................................................56
Figure 43: Example of OCPP Configuration webpage.......................................................57
Figure 44: Example of GUI Configuration webpage..........................................................58
Figure 45: Example of Ethernet Configuration webpage...................................................59
Figure 46: Example of SIM Configuration webpage..........................................................60
Figure 47: Example of the Sim Network Configuration webpage.......................................61
Figure 48: Example of the OpenVPN Configuration webpage...........................................62
Figure 49: Example of the Max Power Configuration webpage.........................................62
Figure 50: Example of the NFC WhiteList webpage..........................................................63
Figure 51: Example of the Password Configuration webpage...........................................64
Figure 52: Example of the JUICE ULTRA Status..............................................................64
Figure 53: Replacing a Power-Stack.................................................................................67
Figure 54: Cooling unit for cooled charging cable (option) ................................................68
List of tables
Table 1: Overview DC power and options JUICE ULTRA product family ..........................10
Table 2: Charging interfaces.............................................................................................15
Table 3: JUICE ULTRA double slot version cabinet components......................................21
Table 4: DC output switchgear components for JUICE ULTRA double slot version ..........23
Table 5: AC input switchgear components for JUICE ULTRA double slot version.............24
Table 6: JUICE ULTRA quadruple slot version cabinet components.................................25
Table 7: DC output switchgear components for JUICE ULTRA quadruple slot version .....27
Table 8: AC input switchgear components for JUICE ULTRA quadruple slot version........28
Table 9: Dimension of the packaging................................................................................29
Table 10: Maximum weight and threat size for eyebolts for different JUICE ULTRA product
types.................................................................................................................................29
Table 11: Distances to keep free for service.....................................................................37
Table 12: Distances between base plate and outer dimensions of charging station..........39
Table 13: Available cable entry plates for JUICE ULTRA-base.........................................44
Table 14: Checks to be carried out before commissioning................................................47
Table 15: Default Charging Station IP address .................................................................48
Table 16: Default Credentials to web interface..................................................................48
Table 17: Naming schema for uploaded files ....................................................................61
Table 18: Error description and troubleshooting................................................................65
Table 19: Periodic maintenance work...............................................................................66
Table 20: Technical data (general)....................................................................................69
Table 21: Mechanical data................................................................................................69
Table 22: Electrical connection for double slot version......................................................69
Table 23: Electrical connection for quadruple slot version.................................................69

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
1Safety instructions
Page 7 of 72
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1. Safety instructions
This chapter contains the safety instruction which must be considered at installation,
operation and maintenance of the JUICE ULTRA 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 JUICE ULTRA ultra-fast charging system.
1.1. Designated use
The JUICE ULTRA 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 JUICE ULTRA. 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 JUICE ULTRA 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 JUICE ULTRA 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 JUICE ULTRA.
Attention
Disregards from these instructions can lead to serious or fatal personal
injury, as well as serious damage to property.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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1Safety instructions
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Attention
Installation and maintenance of the JUICE ULTRA 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 JUICE ULTRA 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 JUICE ULTRA cabinet and do a voltage check
to make sure that the electrical power is disconnected from the system.
Inside the JUICE ULTRA 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 JUICE ULTRA certified technicians are permitted to install,
disassembly, repair or replace components on the JUICE ULTRA. The
JUICE ULTRA cabinet doors has to be locked after installation, service or
repair operations.
Warning of hot surface
Some cabinet internal components of the JUICE ULTRA 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.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
1Safety instructions
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Hints
Pushing the (optionally installed) Stop button (see 2.1.2) on the front door
stops charging/disables charging. The JUICE ULTRA power-stacks will be
turned off.
To turn off the JUICE ULTRA, one can find the main switch (see Figure
28) in the cabinet, rotate the handle to position ‘0’. This will turn off all
internal components of the JUICE ULTRA.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2Product description
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2. Product description
For the JUICE ULTRA charging stations product family two different housings are available,
which can be equipped with various options shown in the following table:
Model
Options
DC-Power
(see chapter 2.2)
Charging Interfaces
(see chapter 2.3)
double slot
version
- 1 power-stack -> 75kW
- 2 power-stacks -> 150kW
- 1 DC charging cable
- 2 DC charging cables
- AC socket with shutter
quadruple
slot
version
- 1 power-stack -> 75kW
- 2 power-stacks -> 150kW
- 3 power-stacks -> 225kW
- 4 power-stacks -> 300kW
- 1 DC charging cable
- 2 DC charging cables
- 3 DC charging cables
- 4 DC charging cables
- AC socket
Table 1: Overview DC power and options JUICE ULTRA product family

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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As shown in the following picture the double slot version can be equipped with one or two
power-stacks:
Figure 1: double slot version with one (left) and two (right) power-stacks
The double slot version can be equipped with up to two DC charging cables and one 22kW
AC socket:
Figure 2: double slot version with two DC charging cables and one AC socket

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2Product description
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As shown in the following picture the quadruple slot version can be equipped with one, two,
three or four power-stacks:
Figure 3: quadruple slot version with one, two, three and four power-stacks
The quadruple slot version can be equipped with up to four DC charging cables and one
22kW AC socket:
Figure 4: quadruple slot version with four DC charging cables and one AC socket
The different cable combinations for DC charging are described in section 2.2 and 2.3.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2.1. Additional Options
2.1.1. Barrier-free JUICE ULTRA
The JUICE ULTRA product line products are optionally available in a barrier-free version
which is designed to be disabled-friendly.
Figure 5: Standard JUICE ULTRA and barrier-free version
2.1.2. Emergency stop button
The emergency stop button was a mandatory requirement of the CHAdeMO 1.0 standard.
With the CHAdeMO 1.1 (June 2016) standard it isn’t anymore a mandatory requirement and
the standard JUICE ULTRA is not equipped with an emergency stop button. The emergency
stop button can be ordered optionally.
2.1.3. Door contact switches
In order to be able to recognize, when the JUICE ULTRA doors are open, there is the
possibility to optionally order door contact switches integrated in the system.
2.1.4. JUICE ULTRA colors
As standard, the JUICE ULTRA is delivered with the housing color Noire 2100 and the
reflector strips on the door have the standard color Pantone 3115 C.
The customer can choose any RAL housing color as well as any RAL reflector strip color as
an option.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2Product description
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2.2. DC-Power
75kW JUICE ULTRA power-stacks are used to supply the DC-charging cables installed on
the JUICE ULTRA. One power-stack can supply only one DC-charging cable at the same
time.
The JUICE ULTRA power-stacks can be switched in parallel mode to increase the power
conducted via one DC-charging cable.
Hint
The usable DC-Power on a DC-outlet is limited by the maximum current of
the used DC-charging cable.
The following picture shows the DC-Power characteristic with one, two, three andfour JUICE
ULTRA power-stacks and different cable types (CCS2 HPC liquid cooled cable, 250A not
liquid cooled GB/T cable, 200A not liquid cooled CCS1 and CCS2 cable, 125A not liquid
cooled CHAdeMO cable)
Figure 6: DC-Power characteristic with one, two, three and four JUICE ULTRA power-stacks and
different cable types

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2.3. Charging interfaces
The following charging interfaces can be selected for the JUICE ULTRA in various
combinations:
Charging interfaces
Charging interface
Max. Voltage capability [V]
Max. current capability [A]
CCS Combo 2 (not liquid
cooled cable)
1.000V DC
200A DC
CCS Combo 2 HPC (liquid
cooled cable)
1.000V DC
500A DC
CHAdeMO (not liquid
cooled cable)
500V DC
125A DC
CCS 1 US (not liquid cooled
cable)*
1.000V DC
200A DC
GB/T China (not liquid
cooled cable)*
750V DC
250A DC
22kW AC Socket Type 2
(with shutter)
400V 3~
32A AC
Table 2: Charging interfaces
Attention
The total performance of the double slot version is limited to a 250A grid
connection.
The total performance of the quadruple slot version is limited to a 500A
grid connection.
Hint
*The CCS 1 and GB/T options are special options for the automotive
industry.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2Product description
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2.4. Nameplate
Depending on the configuration of the charging station, the nameplate may be located on
the device.
2.5. Exterior view
The following figure shows the different connections of the device from the outside.
Figure 7: Elements of the charging station
A DC charge outlet 1
B DC charge outlet 2 (optional)
C AC charge socket (optional)
D air outlet
E air inlet
G Display / HMI
H RFID card reader
I GSM / LTE antenna
J door handle
2.6. Opening of the JUICE ULTRA
The JUICE ULTRA has three doors which allow access to the inside of the device. The
service door andcharging cable door areequipped with a locking cylinder to lock the device.
E
D
D
D
H
G
A B
CJ
D
D
D
E
B
C
A
H
G
J
II

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Version 1-3A
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The cylinder is a ‘10/30 mm profile half cylinder’ which can be replaced by a customer-owned
one.

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2Product description
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Attention
When opening the display door, make sure that the service door is open
before (see the following figure).
Otherwise there is a risk to damage the reflector stripe of the service door.
Figure 8: Order for opening the JUICE ULTRA doors
2° open charging cable door
3° open display door
1° open service door

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The display door can be opened with the release of the locking mechanism behind the
charging cable door, see following picture.
Figure 9: Locking mechanism for the display door

JUICE ULTRA - Operation Instructions and Installation Guide
Version 1-3A
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2.7. Internal view
2.7.1. double slot version internal view
The following figure shows the JUICE BOOSTER’s internal view for the double slot version.
Figure 10:Internal view JUICE ULTRA double slot version (service-, display-, charging cable - side)
The following table describes the single components highlighted in the figures above:
Identifier
Description
-BC1
DC fault current monitoring for AC charging (optional, only when AC-socket is
present)
-BE3
AC meter
-BX1.1, -BX2.1
DC-outlet 1 isolation monitoring device
-BX2.2, -BX1.2
DC-outlet 1 isolation monitoring device (optional, only when DC-outlet 2 is
present)
-EP1
Cooling unit for cooled charging cable (optional, only with cooled charging
cable)
-FB1
32A circuit breaker with fault current monitoring AC charging / 4P
-FB2
16A circuit breaker for auxiliary 230Vac / 4P
-KF1, -KF2
CTRL_COM_HD control board, CTRL_COM Display
-KF3
CTRL_IO control board
-QA1, -QA2
125A circuit breaker / 3P / 16kA
-QB1
-FB2
-QA2
-BX1.1
-QA1
-FB1
-BX2.1
-TB2-TB3
-BX2.2
-BX1.2
-QB1 -TB1
-XD1
-XD2
-XD5
-XD6
-XD7
-XD3
-XD4
-KF3
-KF1
-KF2
-EP1
-SF3
-SF2
-TF1
-EP1
-XF1
-BE3
-QB7
-BC1