Alpitronic Hypercharger HYC200 Installation And Maintenance Manual
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Alpitronic Hypercharger HYC200 Installation And Maintenance Manual

Alpitronic Hypercharger HYC200 Installation And Maintenance Manual

Ultra-fast charging system for electric vehicles
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HYC200 – Installation and Maintenance Manual
Version 1-1
Content
Installation and Maintenance Manual
Hypercharger HYC200
(100 kW – 200 kW)
Ultra-fast charging system for electric vehicles
for HW version 4
All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

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Summary of Contents for Alpitronic Hypercharger HYC200

  • Page 1 Installation and Maintenance Manual Hypercharger HYC200 (100 kW – 200 kW) Ultra-fast charging system for electric vehicles for HW version 4 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 2 HYC200 – Installation and Maintenance Manual Version 1-1 Content This page is intentionally left blank. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 3 Via di Mezzo ai Piani, 33 39100 Bolzano (BZ) ITALY Tel.: +39 0471 1961 333 Fax: +39 0471 1961 451 Homepage: http://www.hypercharger.it E-mail: support@hypercharger.it All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 4 HYC200 – Installation and Maintenance Manual Version 1-1 Content This page is intentionally left blank. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 5 The images included in this manual show a random configuration of the charging station and do not necessarily correspond to your specific setup. The images serve illustrative purposes only. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 6: Table Of Contents

    6.8. Final steps ......................76 7. Commissioning ......................77 8. Diagnosis and parameterisation ..................80 9. Error description and correction ..................81 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 7 13.5. Typical standby power consumption ...............88 Declaration of Conformity ..................89 Table of Figures ..................... 90 List of tables ......................92 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 8 HYC200 – Installation and Maintenance Manual Version 1-1 Content This page is intentionally left blank. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 9: Important Safety Instructions For Installation And Maintenance

    This symbol indicates components or devices that are heavy and can cause injuries if handled carelessly. RISK OF CRUSHING This symbol indicates potential crushing hazards, particularly when installing or transporting equipment. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 10 NOTICE Used to highlight important information about the device or its use, not necessarily related to safety. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 11 • After any intervention, ensure that all doors, openings and protective covers on the HYC200 are securely closed and locked. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 12 2 eyelets on the top of the charging station. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 13 2 m to avoid dangerous voltage flashovers). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 14 4.8.2), the charging process is interrupted/deactivated and the SiC Power-Stacks of the Hypercharger are switched off. Please note possible discharging times of up to 5 minutes. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 15: Intended Use

    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. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 16: Target Group

    If you have any questions, the Hypercharger support team can be reached using the contact details listed above. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 17: Product Description

    - 2 SiC Power-Stacks → 200 kW - 22 kW AC charging socket Table 1: Overview of DC power & charge interfaces Figure 1: DC power equipment All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 18 The order of the charging points with a view of the charging cable door is always from left to right, AC (if available) is last (see Figure 3). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 19: Charging Interfaces

    22 kW AC Type 2 3 x 230 V AC 32 A AC charging socket (with lock) Table 2: Charging interfaces All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 20 The CCS2 charging cables are equipped with temperature sensors that can derate the maximum available charging current when the defined temperature limits are reached. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 21 CCS2 400 A (with boost up to 600 A) • CCS2 and GB/T 250 A • CHAdeMO 125 A Figure 4: DC power characteristics in different configurations All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 22 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 23 The cable management must be ordered separately. For this, turn to sales@hypercharger.it. Instructions for installing the cable management are available on the Hyperdoc document platform. Figure 7: Cable management All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 24: Granularity

    200 kW Connector B 200 kW 150 kW 100 kW 50 kW 0 kW Table 4: Possible distributions of output power All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 25: Exterior View

    4.3. Exterior view The following figure shows the various elements of the device from the outside. Figure 9: HYC200 exterior All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 26: Nameplate

    The nameplate is located opposite the display door in the lower right corner. It contains the CE marking, serial number and electrical characteristics of the charger. Figure 11: Example of a HYC200 nameplate All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 27: Opening The Hypercharger

    Otherwise, there is a risk that the reflector strips of the service door will be damaged. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 28 The display door can be opened by releasing the locking mechanism behind the charging cable door, as shown in the following image. Figure 14: Locking mechanism for the display door All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 29 When closing the doors, follow the correct order once again and ensure that all protective covers have been installed and that the doors have been properly locked. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 30: Interior View

    Door contact switch 1 (optional) -TB2, -TB3 SiC Power-Stacks - XD2 Service socket 230 VAC for maintenance Table 5: HYC200 components (service door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 31 -XD1 Busbars power input -XF1 Ethernet network socket (service) -XF2 Ethernet network socket (client-LAN) Table 6: HYC200 components (display door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 32 DC charging port 1 -XD8 DC charging port 2 (optional) -XD11 AC charging socket (optional) Table 7: HYC200 components (charging cable door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 33 (Australia / China), Type J (Switzerland) Adapter 2: Type D (India), Type H (Israel), Type K (Denmark) For this, please turn to sales@hypercharger.it. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 34: Circuit Diagram

    4 Product description 4.6. Circuit diagram Figure 18 shows the circuit diagram of the HYC200. Figure 18: Circuit diagram of the HYC200 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 35 -XD11 AC charging socket (optional) -XF1 Ethernet network socket (service) -XF2 Ethernet network socket (client-LAN) Table 8: HYC200 circuit diagram legend All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 36: Main Components

    Push the lever all the way in and turn it to the right to turn on the main switch. Figure 20: Turn on the main switch All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 37 At the end, make sure that the lever is correctly removed and repositioned in its support (marked in red). Figure 22: Remove the lever All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 38: Sic Power-Stack

    The dimensions of the SiC Power-Stack are provided in Figure 23, the weight is 110 kg. Figure 23: Dimensions of the SiC Power-Stack All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 39 DC connection block at the top of the SiC Power-Stack. Notice Tighten the screws with a torque of 15 Nm. Figure 25: DC connection block All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 40 Electrical connection data DC connection (output): Parameter Nominal value 150…1000 VDC Operating voltage range 2x 0…150 A Output current Table 12: Electrical connection data DC connection All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 41 In order to be able to carry out a possible SiC Power-Stack upgrade, a corresponding online training course offered by Alpitronic must be completed. Find more at https://training.hypercharger.it/. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 42: Input Switchgear

    The following figure shows the HYC200 AC input switchgear. Figure 26: AC input switchgear (front side) Figure 27: AC input switchgear (back side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 43: Output Switchgear

    4.7.4. Output switchgear The following two figures show the DC output switchgear of the HYC200. Figure 28: DC output switchgear (view from above) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 44 -XD4.2 DC busbar + pole for charging cable connection XD8 (DC output 2) Table 14: Components of the DC output switchgear All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 45: Ctrl_Com

    It contains the modems, the eight-port switch, the SOM and other interfaces to the individual secondary boards of the charging unit. Figure 30: Position of the CTRL_COM in the Hypercharger All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 46 The SIM card slots are designed for Mini SIM cards (“standard size”). The charging station is delivered with an Alpitronic SIM card already installed. A customer SIM card can be inserted. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 47: Display Including Rfid Reader

    MIFARE Classic PCD encryption mechanism (MIFARE Classic 1K/4K) • NFC Forum tag 1-5 (MIFARE Ultralight, Jewel, Open FeliCa Tag, MIFARE DESFire) • ISO/IEC 15693/ICODE VCD mode All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 48: Ctrl_Ext

    The CTRL_EXT is located inside the display door opening, the exact location is marked in the following figure. Figure 33: Position of the CTRL_EXT in the Hypercharger All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 49: Additional Options

    During refilling, the cooling unit should be disconnected from the supply to avoid overflow. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 50: Emergency Stop Switch

    CTRL_EXT board (see chapter 4.7.7), the wiring of which can be routed outside by the customer. Figure 35: Position of the external emergency stop relay in the Hypercharger All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 51: Crash Sensor

    Please note that the crash sensor is installed in the same position in the HYC200 as the external emergency stop relay (see Figure 35). For this reason both options cannot be combined. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 52: Door Contact Switch

    The Hypercharger product family can also optionally be ordered barrier-free. As shown in Figure 37, the screen is offset downwards by 20 cm. Figure 37: Dimensions of the barrier-free Hypercharger (in mm) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 53: Packaging, Transport And Storage

    (= green display) or has fallen (= red display). If the latter is the case, accept the delivery only with reservations and inform logistics@alpitronic.it. Figure 38: HYC200 cardboard packaging All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 54 Table 16: Weight calculation for HYC200 Notice The HYC200, including packaging, can weigh up to 585 kg, depending on the configuration. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 55: Transport And Storage

    To transport the Hypercharger with cardboard packaging by crane, remove the top cover (see Figure 42, point 2) to expose the crane eyelets. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 56 -40°C to +55°C. Be particularly careful when unpacking with knives, the HYC200 or other components could be damaged. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 57: Unpacking The Hypercharger

    It is recommended that you transport the Hypercharger to its final destination in its original packaging and unpack it there. The following images show the order in which the Hypercharger should be unpacked. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 58 HYC200 – Installation and Maintenance Manual Version 1-1 Page 58 of 92 5 Packaging, transport and storage Figure 42: Procedure for unpacking the Hypercharger All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 59 *Notice These screws can be reused during assembly. They are used to mount the Hypercharger on the base (see chapter 6.5). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 60: Mechanical And Electrical Installation

    Type B environments (residential, commercial, and small businesses) may result in undesirable electromagnetic interference. In this case, the user may need to take appropriate remedial action. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 61 IEC 61439-2. A separate document on the design of the network connection is available on the Hyperdoc document platform. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 62: Site Preparation

    Hypercharger, while the prescribed distances represent the absolute minimum for maintenance work, for example to be able to replace a SiC Power-Stacks. Figure 44: Recommended minimum distances for site preparation All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 63 Impairments to air circulation can lead to a reduction in the performance of the charging station. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 64: Placing The Concrete Foundation

    The Hypercharger foundation is designed for wind zones of level 3 (maximum wind speed of 27.5 m/s; wind load q = 0.47 kN/m² and terrain category II. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 65 GW, GI, SW, SI in accordance with DIN 18196 up to the lower edge of the base and compacted in layers. Figure 46: HYC200 on concrete foundation All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 66 0.73 m. The diameter of the side openings is 20 cm. Figure 47: Grid cables bending radius This area may vary depending on the cable length. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 67: Fastening The Base To The Foundation

    The use of the cable entry plate is absolutely necessary! Not using one can cause dust and dirt to build up, which can damage the Hypercharger. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 68 (the positions are engraved on the cable entry plate) and the correct orientation of the base itself: Figure 50: Alignment of base on the foundation All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 69 86 mm (± 3 mm) 357 mm (± 3 mm) 519 mm (± 3 mm) Table 19: Distances from base to external dimensions of HYC200 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 70: Preparing The Grid Cables

    The cable jig can be ordered at sales@hypercharger.it. Attach the cable jig to the base. Figure 52: Cable jig for preparing the grid cables All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 71: Attaching The Hypercharger To The Base

    To do this, the Hypercharger must be removed from the metal pallet. To do this, open all doors of the Hypercharger. Notice Make sure the doors are opened in the correct order (see chapter 4.4). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 72 32 mm washers). Alternatively, 30 or 40 mm washers can also be used. Tighten the screws with a torque of 90 Nm. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 73: Attaching The Grid Cables

    The brass sleeves have a length of 55 mm, an outer diameter of 30 mm and an inner drilling diameter of 13 mm. Figure 55: Brass sleeves on the cable jig All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 74 Tighten the screws with a torque of 35 Nm. Figure 56: Fastening the cable lugs After connecting the grid cables, be sure to attach the appropriate plexiglass covers. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 75 Figure 57: Screw connection of the grid cables to the conductor rails (in mm) Figure 58: Side view of the grid cable connection All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 76: Final Steps

    In addition, the crane eyelets should be removed and the locking screws, which are included in the scope of delivery, should be attached. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 77: Commissioning

    For Hyperdoc registration: https://account.hypercharger.it/register (the digital protocols are only available to appropriately trained technicians (see above)). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 78 Check RFID reader Functional test of the RFID reader • Check connectivity of SIM Check the connection to the Alpitronic backend cards All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 79 • see appendix to calibration Adhesive seal law for details) • Overlay Table 20: Checks to be carried out during commissioning All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 80: Diagnosis And Parameterisation

    Further information about the web interface can be found in the corresponding configuration manual, which is available on the Hyperdoc document platform. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 81: Error Description And Correction

    Start the charging station in charging station diagnostic mode and use the diagnostic tool for further error localization. Table 22: Error description and correction All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 82: Preventive Maintenance

    Failure to maintain an appropriate maintenance protocol may void the warranty. For Hyperdoc registration: https://account.hypercharger.it/register (the digital protocols are only available to appropriately trained technicians (see above)). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 83 Check RFID reader Functional test of the RFID reader • Check connectivity of SIM cards Check the connection to the Alpitronic backend All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 84 Recalibration of measuring devices that are compliant with calibration law • If necessary, functional tests including accuracy tests Table 23: Annual maintenance work All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 85: Reparation And Service

    To order spare parts, contact aftersales@hypercharger.it. Hypercharger support is available around the clock (24/7) by phone on +39 0471 1961 333 or by email (support@hypercharger.it). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 86: Disposal

    Please contact your local authority for suitable collection points. Notice For more information, please contact Hypercharger support or contact a dedicated WEEE Advisory Service directly. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 87: Technical Data

    See Table 16 Table 25: Mechanical data 13.3. Electrical Connection Data Notice The Hyperchargers are intended for direct connection to the supply network. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 88: Radio Communication

    All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 89: Declaration Of Conformity

    HYC200 – Installation and Maintenance Manual Version 1-1 14 Declaration of Conformity Page 89 of 92 14. Declaration of Conformity All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 90: Table Of Figures

    Figure 51: Distances between the base and the external dimensions of the HYC200 ..69 Figure 52: Cable jig for preparing the grid cables ..............70 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.
  • Page 91 Figure 57: Screw connection of the grid cables to the conductor rails (in mm) ....75 Figure 58: Side view of the grid cable connection .............75 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

  • Page 92: List Of Tables

    Table 26: Electrical Connection Data ................88 Table 27: Frequency bands and transmission levels ............88 Table 28: No-load power dissipation at 400 V AC .............88 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of Alpitronic Srl.

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