Fast charging system for electric vehicles (76 pages)
Summary of Contents for Alpitronic Hypercharger HYC400
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Installation and Maintenance Manual hypercharger HYC400 (100 kW – 400 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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HYC400 – Installation and Maintenance Manual Version 2-6 Contents 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.
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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.
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Further documentation is available on hyperdoc for charging stations that have been equipped in accordance with the applicable country- specific measurement and calibration laws. This must be considered. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
6.8. Final steps ......................74 7. Commissioning ......................75 8. Diagnosis and parameterisation ..................78 9. Error description and correction ..................79 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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13.5. Typical standby power consumption ...............86 Declaration of Conformity ..................87 Table of Figures ..................... 91 List of tables ......................93 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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HYC400 – Installation and Maintenance Manual Version 2-6 Contents 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.
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.
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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.
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• After any intervention, ensure that all doors, openings and protective covers on the HYC400 are securely closed and locked. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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4 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.
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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.
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4.8.2), the charging process is interrupted/deactivated and the SiC Power-Stacks of the hypercharger are switched off. Please note possible unloading 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.
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.
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.
(only possible with a maximum of 3 DC charging cables) 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.
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.
The application mixture “innovatek Protect IP 52% Color” is used as a cooling liquid. Only the original, which can be ordered from alpitronic, may be used (sales@hypercharger.it). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
CCS 1/2* CCS 1/2* CCS 1/2 CCS 1/2, CHAdeMO CCS 1/2* * cooled cable possible Table 4: Possible combinations of charging interfaces All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
CCS2 and GB/T 250 A • CCS1 and CHAdeMO 200 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.
The cable radii of the 3.5 and 5 m cables refer to a standard charging height of 0.8 m. Figure 6: Standard charging height of 0.8 m All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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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. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
HYC400 – Installation and Maintenance Manual Version 2-6 Page 24 of 93 4 Product description Figure 7: Cable management Figure 8: Cable management range All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
The distribution depends on various factors such as load management, connected load and the possible charging capacity or power demand of the respective vehicles. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
4 Product description 4.3. Exterior view The following figure shows the various elements of the device from the outside. Figure 9: HYC400 exterior All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
The type plate 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 HYC400 type plate All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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.
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.
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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.
-TB2, -TB3, -TB4, -TB5 SiC Power-Stacks - XD2 Service socket 230 VAC for maintenance Table 6: HYC400 components (service door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
-XD1 Busbars power input -XF1 Ethernet network socket (service) -XF2 Ethernet network socket (client-LAN) Table 7: HYC400 components (display door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
-XD8, -XD9, -XD10 DC charging port 2/3/4 (optional) -XD11 AC charging socket (optional) Table 8: HYC400 components (charging cable door side) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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(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 35 of 93 4.6. Circuit diagram Figure 18 shows the circuit diagram of the HYC400. Figure 18: Circuit diagram of the HYC400 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
-XD11 AC charging socket (optional) -XF1 Ethernet network socket (service) -XF2 Ethernet network socket (client-LAN) Table 9: HYC400 circuit diagram legend All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
The dimensions of the SiC Power-Stack are provided in Figure 19, the weight is 110 kg. Figure 19: 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.
DC connection block at the top of the SiC Power-Stack. Notice Tighten the screws with a torque of 15 Nm. Figure 21: DC connection block All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Electrical connection data DC connection (output): Parameter Nominal value 150…1000 VDC Operating voltage range 2x 0…150 A Output current Table 13: Electrical connection data DC connection All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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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.
630 A Main switch / 4P -TB1 24 V auxiliary supply -XD2 Service socket 230 VAC for maintenance Table 14: Components of the AC input switchgear All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
The following two figures show the DC output switchgear of the HYC400. Figure 23: DC output switchgear (view from below) Figure 24: 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.
DC bus bar + pole for charging cable connection XD10 (DC output 4) Table 15: 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.
It contains the modems, the eight-port switch, the SOM and other interfaces to the individual secondary boards of the charging unit. Figure 25: 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.
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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.
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.
The CTRL_EXT is located inside the display door opening, the exact location is marked in the following figure. Figure 28: 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.
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.
CTRL_EXT board (see chapter 4.7.6), the wiring of which can be routed outside by the customer. Figure 30: 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.
Please note that the crash sensor is installed in the same position in the HYC400 as the external emergency stop relay (see Figure 30). 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.
The hypercharger product family can also optionally be ordered barrier-free. As shown in Figure 32, the screen is offset downwards by 20 cm. Figure 32: 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.
(= 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 33: HYC400 cardboard packaging All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Table 17: Weight calculation for HYC400 Notice The HYC400, including packaging, can weigh up to 1 t depending on the configuration. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
To transport the hypercharger with cardboard packaging by crane, remove the top cover (see Figure 37, point 2) to expose the crane eyes. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
-40°C to +55°C. Be particularly careful when unpacking with knives, the HYC400 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.
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.
HYC400 – Installation and Maintenance Manual Version 2-6 5 Packaging, transport and storage Page 57 of 93 Figure 37: Procedure for unpacking the hypercharger All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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*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.
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.
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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.
SiC Power-Stacks. Figure 38: 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.
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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.
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.
GW, GI, SW, SI in accordance with DIN 18196 up to the lower edge of the base and compacted in layers. Figure 40: HYC400 on concrete foundation All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
0.73 m. The diameter of the side openings is 20 cm. Figure 41: Mains cable 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.
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.
(the positions are engraved on the cable entry plate) and the correct orientation of the base itself: Figure 44: 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.
516 mm (± 3 mm) Table 20: Distances from base to external dimensions of HYC400 The base can now be attached to the concrete foundation. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Now shorten all mains cables to the intended length, fit them with suitable cable lugs and fix them to the ends of the mains cables with suitable crimping pliers. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
To do this, the cooling unit must be unplugged and the fixing screws loosened. All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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.
The brass sleeves have a length of 45 mm, an outer diameter of 30 mm and an inner drilling diameter of 13 mm. Figure 49: 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.
After connecting the mains cables, be sure to attach the appropriate plexiglass covers. Figure 51: Screw connection of the mains cables to the conductor rails (in mm) All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
In addition, the lifting eyes 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.
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.
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Check whether all protective covers have been correctly attached after the electrical installation Check RFID reader Functional test of the RFID reader All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Separate instructions are available on the hyperdoc document platform for operating the HYC400 (details on the charging process, how to proceed in the event of error messages). All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Further information about the webinterface 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.
Start the charging station in charging station diagnostic mode and use the diagnostic tool for further error localization. Table 23: Error description and correction All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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.
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Functional test of the main switch QB1 Verification of the cooling unit Verification of fan & pump noise Check RFID reader Functional test of the RFID reader All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Recalibration of measuring devices that are compliant with calibration law • If necessary, functional tests including accuracy tests Table 24: Annual maintenance work All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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.
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.
See Table 17 Table 26: 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.
Power level Power [W] HYC400 Energy-saving mode 66 W Standby mode 270 W Table 29: No-load power dissipation at 400 V AC All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
HYC400 – Installation and Maintenance Manual Version 2-6 14 Declaration of Conformity Page 87 of 93 Declaration of Conformity All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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HYC400 – Installation and Maintenance Manual Version 2-6 Page 88 of 93 14 Declaration of Conformity All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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HYC400 – Installation and Maintenance Manual Version 2-6 14 Declaration of Conformity Page 89 of 93 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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HYC400 – Installation and Maintenance Manual Version 2-6 Page 90 of 93 14 Declaration of Conformity All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Figure 50: Fastening the cable lugs ..................73 Figure 51: Screw connection of the mains cables to the conductor rails (in mm) ....73 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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HYC400 – Installation and Maintenance Manual Version 2-6 Page 92 of 93 0 Table of Figures Figure 52: Side view of the mains cable connection ............74 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Table 27: Electrical Connection Data ................86 Table 28: Frequency bands and transmission levels ............86 Table 29: No-load power dissipation at 400 V AC .............86 All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
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