Hypercharger Hyc 075

hypercharger - Operation Instructions and Installation Guide
Version 1-1C
Content
Operation Instructions and

Installation Guide
hypercharger 75kW – 300kW

(HYC_075 / HYC_150 / HYC_225 / HYC_300)
ultra-fast charging system for electric vehicles
for HW-Versions 2.x
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization by alpitronic s.r.l.
Version 1-1C
Content
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Version 1-1C
Content
Operation Instructions and

Installation Guide
Version
Version 1-1C of operation instructions and installation guide, 13th June 2018
Original English version
© 2018 alpitronic S.r.l.
All rights reserved. The reproduction of this document, also partially, is allowed only with authorization
by alpitronic S.r.l.. The information in this document is subject to change without notice.
Although the content of this release was carefully checked for accuracy, errors cannot be entirely ruled
out. If you discover an error, please notify us at info@hypercharger.it . alpitronic S.r.l. assumes no
responsibility for any errors that may appear in this document. This document is originally written in
English. Other language versions are a translation of the original document and alpitronic S.r.l. cannot
be held liable for errors in the translation.
alpitronic S.r.l. shall in no event be liable for any direct, indirect, special, incidental or consequential
loss or damages or damages of any other kind (including, without limitation damages for lost profit or
loss of data) arising out of the use of this document.
Manufacturer
alpitronic S.r.l.
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: +39 0471 096450
Fax: +39 0471 096451
Homepage: http://www.hypercharger.it
E-Mail: info@hypercharger.it
Service
alpitronic S.r.l.
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: +39 0471 096450
Fax: +39 0471 096451
Homepage: http://www.hypercharger.it
E-Mail: info@hypercharger.it
Version 1-1C
Content
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
Version 1-1C
Content
Content
1. Safety instructions ...........................................................................................................1
1.1. Designated use ....................................................................................................... 1
1.2. Users ...................................................................................................................... 1
1.3. Safety instructions for installation and maintenance ................................................ 1
1.4. Nameplate............................................................................................................... 4
2. Transport, storage, unpacking and handling ....................................................................5
2.1. Packaging ............................................................................................................... 5
2.2. Transport, handling and storage .............................................................................. 5
2.3. Unpacking ............................................................................................................... 8
3. Product description........................................................................................................10
3.1. Exterior view ..........................................................................................................10
3.2. Site Configuration ...................................................................................................11
3.3. Cable reach ............................................................................................................12
3.4. Opening of the hypercharger ..................................................................................13
3.5. Internal view ...........................................................................................................14
3.5.1. HYC_075 and HYC_150 internal view .............................................................14
3.5.2. HYC_225 and HYC_300 internal view .............................................................18
3.6. Hypercharger configurations ..................................................................................22
3.6.1. HYC_075 configuration ...................................................................................22
4. Mechanical installation ..................................................................................................26
4.1. Concrete foundation ...............................................................................................27
4.2. Adaptor ..................................................................................................................28
4.3. hypercharger-base .................................................................................................28
4.4. Mechanical installation of the hypercharger ............................................................30
5. Electrical installation ......................................................................................................31
5.1. hypercharger schematic for the HYC_075 and the HYC_150 .................................31
5.2. hypercharger schematic for the HYC_225 and the HYC_300 .................................32
5.3. Preparation mains power-supply cables .................................................................33
5.4. Grid Connection .....................................................................................................34
5.5. Checks before initial startup ...................................................................................35
6. Diagnosis and parameterization ....................................................................................36
6.1. User interface .........................................................................................................36
6.2. Diagnosis ...............................................................................................................39
6.3. Parameterization ....................................................................................................42
7. Error description and removal .......................................................................................47
8. Maintenance..................................................................................................................48
8.1. Overview of maintenance work ..............................................................................48
8.2. Replacing a hypercharger power-stack ..................................................................49
8.3. Cooling unit for cooled charging cable (optional) ....................................................50
9. Technical specifications.................................................................................................52
10. Declaration of Conformity .......................................................................................54
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Content
List of figures
Figure 1: Example of Nameplate for hypercharger ............................................................. 4
Figure 2: Vertical and horizontal transport with pallet truck or forklift .................................. 6
Figure 3: Crane eyelets on top of the packaging ................................................................ 6
Figure 4: Unpacking the hypercharger ............................................................................... 9
Figure 5: Elements of the charging station ........................................................................10
Figure 6: Recommended distances for site configuration ..................................................11
Figure 7: Cable reach for the two DC outlets of the hypercharger .....................................12
Figure 8: Order for opening the hypercharger ...................................................................13
Figure 9: Internal view hypercharger HYC_075 and HYC_150 (left, front and right) ..........14
Figure 10: DC output switchgear of the HYC_075 and the HYC_150 ................................16
Figure 11: AC input switchgear of the HYC_075 and the HYC_150 ..................................17
Figure 12: Internal view hypercharger HYC_225 and HYC_300 (left, front and right) ........18
Figure 13: DC output switchgear of the HYC_225 and the HYC_300 (bottom view) .........19
Figure 14: DC output switchgear of the HYC_225 and the HYC_300 (top view) ...............20
Figure 15: AC input switchgear of the HYC_225 and the HYC_300 ..................................21
Figure 16: hypercharger configurations and options .........................................................22
Figure 17: DC output power of the 75kW hypercharger ....................................................23
Figure 18: DC output power of the 150kW hypercharger, whole DC-power on one outlet .23
Figure 19: DC output power of the 225kW hypercharger ..................................................24
Figure 20: DC output power of the 300kW hypercharger, whole DC-power on one outlet .25
Figure 21: Naming of relevant components for the mechanical installation of the
hypercharger ....................................................................................................................26
Figure 22: Distances between base plate and outer dimensions of charging station on the
concrete foundation (HYC_075, HYC_150) (front/top view) ..............................................27
Figure 23: Distances between base plate and outer dimensions of charging station on the
concrete foundation (HYC_225, HYC_300) (front/top view) ..............................................28
Figure 24: hypercharger-base for the HYC_075 and HYC_150 (front/top view left) ..........29
Figure 25: hypercharger-base for the HYC_225 and HYC_300 (front/top view left) ..........29
Figure 26: hypercharger schematic for the HYC_075 and the HYC_150...........................31
Figure 27: hypercharger schematic for the HYC_225 and the HYC_300...........................32
Figure 28: Cable inlet and connection lengths for HYC_075 to HYC_300 .........................33
Figure 29: Connecting of the input Busbars (HYC_075/150 left, HYC_225/300 right) .......34
Figure 30: Credentials form shown at first connection with web interface..........................36
Figure 31: Home screen of web interface..........................................................................37
Figure 32: Example of SIM Signal webpage .....................................................................39
Figure 33: Example of Process View webpage .................................................................40
Figure 34: Example of Stop Button webpage ....................................................................41
Figure 35: Example of BOOT Configuration webpage.......................................................42
Figure 36: Example of OCPP Configuration webpage.......................................................43
Figure 37: Example of GUI Configuration webpage ..........................................................44
Figure 38: Example of Ethernet Configuration webpage ...................................................45
Figure 39: Example of SIM Configuration webpage ..........................................................46
Figure 40: Example of the Password Configuration webpage ...........................................46
Figure 41: Replacing a Power-Stack .................................................................................49
Figure 42: Cooling unit for cooled charging cable (option) ................................................50
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Content
List of tables
Table 1: Dimension of the packaging ................................................................................. 5
Table 2: Maximum weight and threat size for eyebolts for the whole hypercharger product
range ................................................................................................................................. 7
Table 3: Distances to keep free for service .......................................................................12
Table 4: hypercharger HYC_075 and HYC_150 cabinet components ...............................15
Table 5: DC output switchgear components for hypercharger HYC_075 and HYC_150 ...17
Table 6: AC input switchgear components for hypercharger HYC_075 and HYC_150 ......17
Table 7: hypercharger HYC_225 and HYC_300 cabinet components ...............................19
Table 8: DC output switchgear components for hypercharger HYC_225 and HYC_300 ...20
Table 9: AC input switchgear components for hypercharger HYC_225 and HYC_300 ......21
Table 10: Distances between base plate and outer dimensions of charging station ..........27
Table 11: Available cable entry adaptor plates for hypercharger-base (not available yet) .33
Table 12: Checks to be carried out before commissioning ................................................35
Table 13: Default Charging Station IP address .................................................................36
Table 14: Default Credentials to web interface ..................................................................36
Table 15: Error description and troubleshooting ................................................................47
Table 16: Periodic maintenance work ...............................................................................48
Table 17: Relation frost protection to dilution ratio ............................................................51
Table 18: Technical data (general)....................................................................................52
Table 19: Mechanical data ................................................................................................52
Table 20: Electrical connection for HYC_075 ....................................................................52
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1 Safety instructions Page 1 of 57
1. Safety instructions
This chapter contains the safety instruction which have to be considered at installation,
operation and maintenance of the hypercharger ultra-fast charging system for electric
vehicles. Incorrect operation as a result of non-compliance with the operation instructions
may lead to severe injuries or damages. This safety operation must be read carefully
before the installation, operation and maintenance of the test bench.
1.1. Designated use

The hypercharger ultra-fast charging system for electric vehicles is intended to be used
both in indoor and outdoor environments for performing ultra-fast charging for electric
vehicles.
Attention
The charging station is designed for a stationary installation in an

ambient with pollution degree class 3.
For the connection between the electric vehicle supply equipment

(EVSE) and electric vehicle (EV), no additional cables are required
besides from the one provided with the hypercharger. A charging cord
should not be altered to extend or divide the cable range.
No adapters may be used which are not approved by the vehicle

manufacturer.
Depending on a socket or vehicle coupling the hypercharger may only

changer a single vehicle. Y-cables or similar are not allowed.
1.2. Users
These operation instructions and installation guide are intended for persons who are
responsible to install, operate, service and maintain the hypercharger ultra-fast charging
system for electric vehicles. These persons should have at least a basic knowledge of
electrical high power systems and electric vehicles. Prior to carrying out any work the
operator and the responsible technical personnel must carefully read these instructions.
1.3. Safety instructions for installation and maintenance

This warnings and instructions apply to all activities of installation, service and
maintenance on the hypercharger.
Disregards from these instructions can lead to serious or fatal personal

injury, as well as serious damage to property.
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Page 2 of 57 1 Safety instructions
Attention
Installation and maintenance of the hypercharger ultra-fast charging

system for electric vehicles must only be carried out by qualified
personnel.
Before putting the system into operation, check the correct state of the
installation and all connections.
Electrostatic discharge
The control cabinet contains components and circuit boards that are
sensitive to electrostatic discharge. During assembly and
maintenance, sufficient ESD measures should be taken to protect the
electronic components (for example, wearing a grounding wristband).
Warnings
Warning of hazardous electrical voltage
Installation and maintenance of the test bench must be carried out only
when power is removed. Before performing any installation, disassembly,
repair or replacement of components, switch off the external group switch
and the main switch in the hypercharger cabinet and do a voltage check
to make sure that the electrical power is disconnected from the system.
Inside the hypercharger cabinet, hazardous electrical voltages are

present (up to 1000Vdc) even if all circuit breakers are switched off, do
not allow unqualified persons to go near it.
Only hypercharger certified technicians are permitted to install,

disassembly, repair or replace components on the hypercharger. The
hypercharger cabinet doors has to be locked after installation, service or
repair operations.
Warning of hot surface
Some cabinet internal components of the hypercharger like power stack

housings, cooling system, and conductors can remain hot long after the
power supply has been disconnected.
Prior to performing disassembly, repair or replacement of components

activities make sure that all components have cooled down.
Heavy weight
Please note that the individual components of the device can be very
heavy, for example the power-stacks.
Crushing
Please take care when assembling and disassembling components that

they do not squeeze a human body or body part.
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1 Safety instructions Page 3 of 57
Hints
Pushing the (optionally installed) Stop button (see Fehler!

Verweisquelle konnte nicht gefunden werden.) on the front door stops
charging/disables charging. The hypercharger power stacks will be
turned off.
To turn off the hypercharger, one can find the main switch (see Figure
26) in the cabinet, rotate the handle to position ‘0’. This will turn off all the
main components of the hypercharger.
Version 1-1C
Page 4 of 57 1 Safety instructions
1.4. Nameplate
Depending on the configuration of the charging station, the following nameplate (example)
may be located on the device.
Mady in Italy by
alpitronic GmbH
Bozner Boden Mitterweg 33
I-39100 Bozen
Modell: HYC_075 / HYC_150 SERIAL NR: 18BZ00001

Manufactured: 04/2018
HW-Revision: 2.0
Main voltage: 3x 400 (±10%) Vac
Frequency: 50 (±5%) Hz
Maximal input current: 250 A
Degree of protection: IP54
Charging voltage range: 150…1000 Vdc
Max. Weight: 400 kg
Figure 1: Example of Nameplate for hypercharger
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2 Transport, storage, unpacking and handling Page 5 of 57
2. Transport, storage, unpacking and handling

2.1. Packaging
The hypercharger is delivered in a specialized wood packaging. The following figure shows
the packaging, and size information for the two charger types.
W
Type W [mm] D [mm] H [mm]

HYC_075, HYC_150 1200 800 2340
HYC_225, HYC_300 1200 1120 2340
Table 1: Dimension of the packaging
2.2. Transport, handling and storage

In its wood packaging, the hypercharger can be transported vertically as well as
horizontally, this allows flexibility in transportation. It can be transported in ordinary trucks
as well as in vans (horizontal position during transport).
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Page 6 of 57 2 Transport, storage, unpacking and handling
Figure 2: Vertical and horizontal transport with pallet truck or forklift
In addition to the transport with a pallet truck or a forklift, the hypercharger can also be
moved using the two crane eyelets which are on top of the packaging.
Figure 3: Crane eyelets on top of the packaging
Version 1-1C
Attention
The hypercharger must be stored in its original packaging in a dry

environment from -40°C to +55°C.
The following table contains the weight indication for the single hypercharger types:
Type Weight Weight Threat size

hypercharger [kg] packaging [kg] for eyebolts
HYC_075 300 140 M12
HYC_150 400 140 M12
HYC_225 550 160 M12
HYC_300 650 160 M12
Table 2: Maximum weight and threat size for eyebolts for the whole hypercharger product range
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Page 8 of 57 2 Transport, storage, unpacking and handling
2.3. Unpacking
It is recommended to transport the hypercharger to its final destination in its original
packaging and unpack it there. The following illustrations show the sequence to unpack
the hypercharger:
Unpacking the hypercharger

1 2 3 4 5
Remove the Remove bands Lift top cover Remove Remove rear panel
hypercharger-base screws on
rear panel
6 7 8 9 10
Remove side Remove screws Remove rear panel Open left Remove screws on
panels between panel side door the base plate of the
and pallet hypercharger
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11 12 13 14 15
Open right side Open front door Remove front acrylic Remove Close all doors, lift
door glass cover screws on the the hypercharger
base plate of with a crane and
the remove the pallet
hypercharger
Figure 4: Unpacking the hypercharger
The outer packaging is made of 100% recyclable wood, the inner packaging is made of
plastic and must be disposed separately.
Version 1-1C
Page 10 of 57 3 Product description
3. Product description
The HYC_075 and the HYC_150 of the hypercharger product family have the same
housing and in the case of the HYC_075 the housing is equipped with one 75kW
hypercharger power stack. The HYC_150 is equipped with two hypercharger power stacks
(each 75kW) and has a nominal power of 150kW.
The HYC_225 and the HYC_300 of the hypercharger product family have the same but
larger housing and in the case of the HYC_225 the housing is equipped with three 75kW
hypercharger power stack. The HYC_300 is equipped with four hypercharger power stacks
(each 75kW) and has a nominal power of 300kW.
3.1. Exterior view

The following figure shows the different connections of the device from the outside.
Figure 5: Elements of the charging station
A DC charge outlet 1
B DC charge outlet 2 (optional)
C AC charge socket (optional)
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3 Product description Page 11 of 57
D air outlet
E air inlet
F Stop button (optional)
G Display / HMI
H RFID card reader
I GSM / LTE / WLAN antenna
J door handle
3.2. Site Configuration

When installing the hypercharger, it must be ensured to give certain a minimum distance
from possible objects around the hypercharger, to allow adequate airflow, and secondly,
space for possible service or maintenance operations.
Attention
A mechanical ramming protection with sufficient stability should be

provided to protect the charging station.
The following figure shows the recommended minimum distances which should be kept
free during installation on site:
Figure 6: Recommended distances for site configuration

The figure above shows the hypercharger housing for the HYC_075 and the HYC_150, the
distances for the HYC_225 and the HYC_300 can be found in the following table.
Version 1-1C
Type W1 [mm] D1 [mm] D2 [mm] D3[mm] L [mm]

HYC_075, HYC_150 854 1100 350 1000 420
HYC_225, HYC_300 854 1100 350 1000 732
Table 3: Distances to keep free for service
Attention
The legal minimum widths for escape routes must be respected in any
case.
To allow easy replacement of the power-stacks, a clearance of at least 110cm must be

available on the left side (see D1).
At least a distance of 1100mm (D1) and 1000mm (D3) must be maintained in front of the
ventilation grilles to not impair the circulation of the supply and exhaust air. It must also be
prevented that the exhaust air is reintroduced into the supply air circuit.
Impairments to the air circulation may lead to a reduced efficiency of the charging station.
3.3. Cable reach

In its default configuration, the hypercharger comes with a cable length of 350cm. The
following figure shows the operating radius (3m) of the cables for the two DC outlets of the
hypercharger.
Figure 7: Cable reach for the two DC outlets of the hypercharger
Version 1-1C
3.4. Opening of the hypercharger

The hypercharger has three doors which allow access to the inside of the device. The two
narrow doors are equipped with a locking cylinder to lock the device. The cylinder is a
‘10/30 mm profile half cylinder’ which can be replaced by a customer-owned one.
Attention
When opening the front door, make sure that the left side door is open
before (see the following figure).
2° open door on the right
3° open door in the middle
1° open door on the left
Figure 8: Order for opening the hypercharger
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3.5. Internal view
3.5.1. HYC_075 and HYC_150 internal view
The following figure shows the hypercharger’s internal view for the HYC_075 and the
HYC_150 configurations.
Figure 9: Internal view hypercharger HYC_075 and HYC_150 (left, front and right)
The following table describes the single components highlighted in the figures above:
Identifier Description
DC fault current monitoring for AC charging (optional, only when AC-socket is
-BC1
present)
-BE3 AC meter
-BX1.1, -BX2.1 DC-outlet 1 isolation monitoring device
DC-outlet 1 isolation monitoring device (optional, only when DC-outlet 2 is
-BX2.2, -BX1.2
present)
Cooling unit for cooled charging cable (optional, only with cooled charging
-EP1
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
Version 1-1C
-KF3 CTRL_IO control board
-QA1, -QA2 125A circuit breaker / 3P / 16kA
-QB1 250A main switch / 4P
-QB2, -QB3,
Contactors for DC charging
-QB4
-QB7 Contactors for AC charging (optional, only when AC-socket is present)
-TB1 Auxiliary 24V power supply
-TB2, -TB3 hypercharger power stacks
-TF1 Antenna (3G, LTE or WLAN)
-XD1 Mains input busbars
-XD2 Power socket 230Vac for service
-XD3 DC-busbar for vehicle cable connection XD5 (DC-outlet 1)
DC-busbar for vehicle cable connection XD6 (optional, only when DC-outlet 2
-XD4
is present)
-XD5 DC charge outlet 1
-XD6 DC charge outlet 2 (optional)
-XD7 AC socket (optional, only when AC-socket is present)
-XF1 Ethernet network-dose
Table 4: hypercharger HYC_075 and HYC_150 cabinet components
Version 1-1C
The following figure shows the DC-output switchgear of the HYC_075 and the HYC150:
Figure 10: DC output switchgear of the HYC_075 and the HYC_150
The following table describes the single components highlighted in the table above:
-BC1
present)
-BE1 DC-meter for DC-outlet 1
-BE2 DC-meter for DC-outlet 2 (optional)
-BE3 AC meter
-BX2.2, -BX1.2
present)
-FC1.1, FC1.2 DC-outlet 1 fuses
Version 1-1C
-QB2.1, -QB2.2 DC-outlet 1 contactors
-QB3.1, -QB3.2 DC-outlet 2 contactors (optional, only when DC-outlet 2 is present)
-QB4.1, -QB4.2 DC-link contactors
-XD3.1 DC-busbar + pole for vehicle cable connection XD5 (DC-outlet 1)
-XD3.2 DC-busbar – pole for vehicle cable connection XD5 (DC-outlet 1)
Table 5: DC output switchgear components for hypercharger HYC_075 and HYC_150
The following figure shows the AC input switchgear of the HYC_075 and the HYC_150:
Figure 11: AC input switchgear of the HYC_075 and the HYC_150
The following table describes the single components highlighted in the figure above:
-FA1 Lightning protection and EMI filter device
-FB2 16A circuit breaker with fault current monitoring for auxiliary 230Vac / 4P
-QA1, -QA2 125A circuit breaker / 3P / 16kA
-XF1 Ethernet network dose RJ45
Table 6: AC input switchgear components for hypercharger HYC_075 and HYC_150
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3.5.2. HYC_225 and HYC_300 internal view
The following figure shows the hypercharger internal view for the HYC_225 and the
HYC_300.
Figure 12: Internal view hypercharger HYC_225 and HYC_300 (left, front and right)
The following table describes the single components highlighted in the figures above:
-BC1
present)
-BE3 AC meter
-BX2.2, -BX1.2
present)
Cooling unit for cooled charging cable (optional, only with cooled charging
-EP1
cable)
-FB2 16A circuit breaker for auxiliary 230Vac / 4P
-KF1, -KF2 CTRL_COM_HD control board, CTRL_COM Display
-QA1, -QA2,
125A circuit breaker / 3P / 16kA
-QA3, -QA4
-QB2, -QB3 DC-outlet contactors
-QB4, -QB5,
Contactors for internal DC link
-QB6
Version 1-1C
-TB2, -TB3,
hypercharger power stacks
-TB4, -TB5
-TF1 Antenna (3G, LTE or WLAN)
-XD2 Power socket 230Vac for service
-XD3 DC-busbar for vehicle cable connection XD5 (DC-outlet 1)
DC-busbar for vehicle cable connection XD6 (optional, only when DC-outlet 2
-XD4
is present)
-XD5 AC socket (optional, only when AC-socket is present)
-XD6 DC charge outlet 1
-XD7 DC charge outlet 2 (optional)
-XF1 Ethernet network-dose RJ45
Table 7: hypercharger HYC_225 and HYC_300 cabinet components
The following figure shows the DC-output switchgear of the HYC_225 and the HYC_300:
Figure 13: DC output switchgear of the HYC_225 and the HYC_300 (bottom view)
Version 1-1C
Figure 14: DC output switchgear of the HYC_225 and the HYC_300 (top view)
The following table describes the single components highlighted in the table above:
-BC1
present)
-BE1 DC-meter for DC-outlet 1
-BE2 DC-meter for DC-outlet 2 (optional)
-BE3 AC meter
-BX2.2, -BX1.2
present)
-QB2.1, -QB2.2 DC-outlet 1 contactors
-QB3.1, -QB3.2 DC-outlet 2 contactors (optional, only when DC-outlet 2 is present)
-QB4.1, -QB4.2
-QB5.1, -QB5.2 DC-link contactors
-QB6.1, -QB5.2
Table 8: DC output switchgear components for hypercharger HYC_225 and HYC_300
Version 1-1C
The following figure shows the AC input switchgear of the HYC_225 and the HYC_300:
Figure 15: AC input switchgear of the HYC_225 and the HYC_300
The following table describes the single components highlighted in the figure above:
-FA1 Lightning protection and EMI filter device
-FB2 16A circuit breaker with fault current monitoring for auxiliary 230Vac / 4P
-QA1, -QA2,
125A circuit breaker / 3P / 16kA
-QA3, -QA4
-XF1 Ethernet network dose
Table 9: AC input switchgear components for hypercharger HYC_225 and HYC_300
Version 1-1C
3.6. Hypercharger configurations

There is a variable number of internal components which depend on the configuration of
the hypercharger. The following table shows the possible configurations of the products
within each product family:
Figure 16: hypercharger configurations and options
3.6.1. HYC_075 configuration
The hypercharger with 75kW has one built-in 75kW hypercharger power-stack and can
charge one vehicle with DC at the same time. However, it is possible to equip a 75kW
hypercharger with two DC-outlets (CCS and CHAdeMO) where only one vehicle can be
charged with one of the two DC-outlet types (there is no simultaneous charging of two
vehicles possible). In addition, it is possible to have one 22kW AC socket installed.
The following figure shows the DC output power of the 75kW hypercharger:
Version 1-1C
Figure 17: DC output power of the 75kW hypercharger
The hypercharger with 150kW has two built-in 75kW hypercharger power-stacks and can
charge up to two vehicles at the same time with DC when equipped with two DC outlets
(one per stack, maximum 75kW / vehicle, DC output power see Figure 17).
If a vehicle to be charged requires a charging power greater than 75kW, both hypercharger
power-stacks are to be switched to a DC outlet, which can than provide a charging power
of up to 150kW (DC output power see Figure 18). In addition, it is possible to have a 22kW
AC socket installed.
The following figure shows the DC output power of the 150kW hypercharger, where the
whole power is switched to one DC-outlet:
Figure 18: DC output power of the 150kW hypercharger, whole DC-power on one outlet
Version 1-1C
Attention
The total performance of the 150kW hypercharger is limited to one 250A

grid connection.
The hypercharger with 225kW has three built-in 75kW hypercharger power-stack and can
charge two vehicle with DC at the same time. However, it is possible to equip a 225kW
hypercharger with two DC-outlets (CCS and CHAdeMO) where each vehicle can be
charged with a DC-outlet power. In addition, it is possible to have one 22kW AC socket
installed.
The following figure shows the DC output power of the 225kW hypercharger:
Figure 19: DC output power of the 225kW hypercharger
The hypercharger with 300kW has four built-in 75kW hypercharger power-stacks and can
charge up to two vehicles at the same time with DC when equipped with two DC outlets.
If a vehicle to be charged requires a charging power greater than 75kW, multiple

hypercharger power-stacks can be switched to a DC outlet, which can than provide a
charging power of up to 2x150kW (DC output power see Figure 18) or 1x 300kW. In
addition, it is possible to have a 22kW AC socket installed.
The following figure shows the DC output power of the 300kW hypercharger, where the
whole power is switched to one DC-outlet:
Version 1-1C
Figure 20: DC output power of the 300kW hypercharger, whole DC-power on one outlet
Attention
The total performance of the 300kW hypercharger is limited to one 500A

grid connection.
Due to the modular concept, variants may also occur in which e.g. in a HYC_300 only one
or two stacks are installed. In this case, the DC output power is correspondingly different.
Version 1-1C
Page 26 of 57 4 Mechanical installation
4. Mechanical installation
The mounting of the hypercharger has to be performed on a solid ground, this can be a
concrete foundation or a concrete floor. When dimensioning the foundation, it’s
recommended to perform a static load capacity analysis according to relevant norms.
The following figure defines the naming of relevant components for the mechanical
installation:
WOL WOR WC
Cables
hypercharger
hypercharger-
base
Ground
WI + WIB WI + WIB
adaptor (only for
standard foundation)
Concrete foundation
Figure 21: Naming of relevant components for the mechanical installation of the hypercharger
The mains power-supply cables for connecting the hypercharger to the grid are guided
from the ground over the foundation to the hypercharger. The mechanical mounting of the
hypercharger to the concrete foundation can be performed either directly or via an adaptor
if the foundation is a universal foundation.
Version 1-1C
4 Mechanical installation Page 27 of 57
Attention
Before installation, compliance with all legal requirements for the

installation site (for example, stability against tipping, impact protection,
effects of frost, etc.) must be checked.
Each outlet or each vehicle clutch must be arranged in consideration of

the ergonomics and mechanical impact protection, as close as possible
to the car park to be supplied.
4.1. Concrete foundation

The base plate is arranged eccentrically to the charging station. The outer dimensions
related to the center of the base plate are shown in Figure 22.
Figure 22: Distances between base plate and outer dimensions of charging station on the concrete
foundation (HYC_075, HYC_150) (front/top view)
Distance HYC_075, HYC_150 HYC_225, HYC_300

DC 420 mm 420 mm
DI 100 mm 235 mm
DIB 36 mm (± 3 mm) 36 mm (± 3 mm)
DO 210 mm (± 3 mm) 366 mm (± 3 mm)
WC 300 mm 300 mm
WI 200 mm 200 mm
W IB 86 mm (± 3 mm) 86 mm (± 3 mm)
W OL 357 mm (± 3 mm) 357 mm (± 3 mm)
W OR 519 mm (± 3 mm) 516 mm (± 3 mm)
Table 10: Distances between base plate and outer dimensions of charging station
Version 1-1C
Figure 23: Distances between base plate and outer dimensions of charging station on the concrete
foundation (HYC_225, HYC_300) (front/top view)
4.2. Adaptor
A hypercharger adaptor is only needed if a universal foundation (e.g. UNIMI QC) is used.
In this case, the adaptor is screwed to the foundation with screws on standard positions
(defined by the used foundation) and the hypercharger-base is screwed together with the
adaptor (see the following chapter).
To realize the mechanical mounting of the hypercharger on the concrete foundation, the
foundation must be equipped with minimal four M12 metric screw threads, in the following
positions:
Suitable washers are to be provide. To realize the mains power-supply from the ground,
the cable outlets in the foundation need to be in the middle of the hypercharger-base /
Mounting threads of the foundation:
4.3. hypercharger-base
The hypercharger-base needs a gap of 50mm from the ground level facilitate the
connection of the mains-side supply cables.
The following figure shows the hypercharger-base for the HYC_075 and the HYC_150:
Version 1-1C
4 Mechanical installation Page 29 of 57
400
200 20
200
272
286 286
50
572
Figure 24: hypercharger-base for the HYC_075 and HYC_150 (front/top view left)
The following figure shows the hypercharger-base for the HYC_225 and the HYC_300:
400
Ø20mm
546
470
50
572
Figure 25: hypercharger-base for the HYC_225 and HYC_300 (front/top view left)
Suitable washers are to be provide. The hypercharger-base is to screw together with the
concrete foundation or with the adaptor (in the case a universal foundation is used) by 4x
M12x30 screws and washers (M12 x 35mm / delivered together with the hypercharger).
The screws are to be tightened with a torque of 90Nm.
For the hypercharge-base different cable entry adaptor-plates are available to enable
different mains power-supply cables (details in chapter 5.3).
Version 1-1C
4.4. Mechanical installation of the hypercharger

It is recommended to install the hypercharger according the following steps:
- Preparation of the foundation (see chapter 4.1)
- Mounting of the adaptor to the concrete foundation (see chapter 4.2), only if a universal
foundation is used
- Mounting of the hypercharger base (see chapter 4.3)
- Preparation of the mains power-supply (see chapter 5.3)
- Lift the hypercharger with a crane on the hypercharger base
- Screw the hypercharger via 4x M12x30 screws and 35mm washers together to the
hypercharger-base. The screws are to be tightened with a torque of 90Nm. It’s
preferable to use self-locking thread lock washers.
- Connect the mains power-supply (see chapter 5.4)
Version 1-1C
5 Electrical installation Page 31 of 57
5. Electrical installation
The dimensioning of the cables and the protection devices outside the hypercharger are to
be done according the local regulations and in order to respect the technical specification
of the hypercharger stated in chapter 9.
5.1. hypercharger schematic for the HYC_075 and the HYC_150

The following figure shows the schematic of the hypercharger for the HYC_075 and the
HYC_150:
-XD6 -XD5
CCS or CCS or
CHADEMO CHADEMO
HYC -XD7 AC-CCS
DC-output -XD4 -XD3 4

switchgear -BE2 -BE1
Wh Wh
-BE3
I/U I/U Wh
-FC2 -KF3 -FC1
CTRL_IO
-BC1
-BX2 -BX1 2 DI<6mA AC-Charging
2
<R <R (option)
-QB3 -QB2 -QB7

-QB4 -TF1
2 2 2 4
-TB3 -TB2 -KF1

Türkontakt
CTRL_COM -SF2 -SF3
STACK HD
(AC/DC)
STACK
(option)
(HYC_150 (AC/DC)
STOP
only) -KF2
-SF1
CTRL_COM
Display
(option)
AC input
switchgear
-QA2 -QA1
125A 125A
3 10kA 3 10kA
GRID -QB1
-XD1
4
main
3+N+PE
switch -FB1
4
30mA/32A Cooling unit
10kA
-TB1 -EP1
-FB2 24VDC
4
M
-FA1 30mA/16A 3
10kA 400V ~
lightning (option)
-XD2 -XF1
protection Power socket
2 230Vac Ethernet
(RJ45)
Figure 26: hypercharger schematic for the HYC_075 and the HYC_150
Version 1-1C
Page 32 of 57 5 Electrical installation
5.2. hypercharger schematic for the HYC_225 and the HYC_300

The following figure shows the schematic of the hypercharger for the HYC_225 and the
HYC_300:
-XD7 -XD6
CCS or CCS or
CHADEMO CHADEMO
HYC -XD5 AC-CCS
DC-output -XD4 -XD3

switchgear -BE2 -BE1 4
Wh Wh
-BE3
I/U I/U Wh
-FC2 -KF3 -FC1
CTRL_IO
-BC1
-BX2 -BX1 2 DI<6mA AC-Charging
2
<R <R (optional)
-QB3 -QB2 -QB7

-QB6 -QB5 -QB4 -TF1
2 2 2 2 2 4
-TB5 -TB4 -TB3 -TB2 -KF1

Door contact
CTRL_COM -SF2 -SF3
HD
STACK
(AC/DC) STACK STACK STACK
(option)
(HYC_300
(AC/DC) (AC/DC) (AC/DC)
STOP
only) -KF2
-SF1
CTRL_COM
Display
(option)
AC input
switchgear
-QA4 -QA3 -QA2 -QA1
125A 125A 125A 125A
3 10kA 3 10kA 3 10kA 3 10kA
GRID -QB1
-XD1
4
main
3+N+PE
switch -FB1
4
30mA/32A Cooling unit
10kA
-TB1 -EP1
-FB2 24VDC
4
M
-FA1 30mA/16A 3
10kA 400V ~
lightning (option)
-XD2 -XF1
protection Power socket
2 230Vac Ethernet
(RJ45)
Figure 27: hypercharger schematic for the HYC_225 and the HYC_300
Version 1-1C
5.3. Preparation mains power-supply cables

After the hypercharger-base (see chapter 4.3) is mounted, the mains-side cables should
be conducted through foundation and hypercharger-base. Then the mains-side cables
should be fixed by tightening the cable gland.
For the hypercharge-base different cable entry adaptor-plates are available to enable
different mains power-supply cable types:
Single supply cable Multiple supply cable

HYC_075 / HYC_150 1 x M65 Hole for 3 different cable 5 x M40 Hole for cable glands
glands with a clamping range of: with a clamping range of:
27-39mm 19-28mm
34-45mm
44-55mm
1 x M20 Hole for cable glands
1 x M20 Hole for a cable gland with a clamping range of:
with a clamping range of: 7-13mm
7-13mm
HYC_225 / HYC_300 2 x M65 Hole for 3 different cable 8 x M40 Hole for cable glands
glands with a clamping range of: with a clamping range of:
27-39mm 19-28mm
34-45mm
44-55mm
1 x M20 Hole for cable glands
1 x M20 Hole for a cable gland with a clamping range of:
with a clamping range of: 7-13mm
7-13mm
Table 11: Available cable entry adaptor plates for hypercharger-base (not available yet)
The necessary cable entry adaptor plate depends on the used mains power-supply cable
and should be defined during the ordering of the hypercharger.
Afterwards the M12 cable lugs can be mounted on the positions defined in Figure 28.
Figure 28: Cable inlet and connection lengths for HYC_075 to HYC_300
Version 1-1C
Page 34 of 57 5 Electrical installation
5.4. Grid Connection

The hypercharger charging stations can be used in supply networks of the type TT and
TN-S.
Attention
The necessary protective measures against electric shock and other

country-specific requirements must be taken into account.
Depending on the configuration of the hypercharger and the EMC

measures, the protective conductor current can cause protective
conductor currents up to 1A. Please take this into account when
designing the protective earthing and protective measures.
After the hypercharger is mechanically installed (4.4), the main-side supply cables can be
connected to the hypercharger input Busbars:
Figure 29: Connecting of the input Busbars (HYC_075/150 left, HYC_225/300 right)
The screws M12x25 should be tightening with a torque of 35Nm.
If an active cooled Cable is used (option), the cooling unit for cooled charging cable should
be removed during grid connection (see 8.3.).
Version 1-1C
5.5. Checks before initial startup

The operation of this charging station must be carried out taking into account the test and
maintenance instructions described below. All instructions listed below are considered
mandatory and must be carried out by the operator of the charging station.
After transport and installation, check the following points:
Check Execution
Mechanical visual Mechanically perfect condition of all installed devices (no visible
inspection breakages)
Screw connections, Random or complete testing of tightening torques at terminals and
tight fit mechanical screw connections. Check the terminals and equipment
for tightness.
The transport may have released the swrews.
Earthing system Checking the earthing taking into account the site-specific conditions
as well as the valid standards.
Upstream protection Checking of the supplied charging station regarding the upstream
device protective device according to ISO 61439-2/-7 as well as deviating
country-specific standards and directives
Selectivity Checking the selectivity taking into account the safety elements used
and upstream of the control cabinet in accordance with ISO 61439-2
as well as other country-specific standards
Operating conditions Consideration of the operating conditions at the installation site (e.g.
mechanical, chemical, corrosive stress) according to ISO 61439-2/-7
as well as deviating country-specific standards
Protection cover If the protective cover of the control cabinet has been re-installed
after connecting the main supply line, the contact protection is
provided.
Residual current protection Checking whether a residual current circuit breaker is required for
device operation, taking into account the site-specific conditions and the
valid standards, and whether the residual current protection device is
available
Short circuit resistance Rated current and short-circuit resistance of the main busbar system
taking into account the upstream protective device according to ISO
61439-2/-7
Automatic shutdown of the the requirements of IEC 60364-4-41, section 411 must be met
power supply
Table 12: Checks to be carried out before commissioning
Version 1-1C
Page 36 of 57 6 Diagnosis and parameterization
6. Diagnosis and parameterization

After successful mechanical and electrical installation of the charging station, the correct
functioning of the device can be checked by means of a diagnostic and parameterization
tool. The diagnostic interface can be loaded via any browser at the default IP address as
shown in Table 13.
Default IP address 192.168.1.100

Table 13: Default Charging Station IP address
6.1. User interface

On the first connection to the web interface, one can find a prompt for the username and
the password, like presented in Figure 30.
Figure 30: Credentials form shown at first connection with web interface
Type the default username and password, as shows in Table 14. Please note that for
security reasons, it is important to change the username and password.
Default Credentials
Username admin
Password admin123
Table 14: Default Credentials to web interface
Version 1-1C
6 Diagnosis and parameterization Page 37 of 57
Figure 31 shows the home page. There are five links to other pages. The Diagnostics and
Parameterization options are both present on this same page.
Figure 31: Home screen of web interface
Here is a list of all functionalities of the web interface and where they are found in their
corresponding menus.
Links for Diagnosis category:

 To check the SIM Signal, you can navigate to ‘NETWORK’ from the main menu
and then following the top menu ‘SIM Signal’ can be found.
 To check the currently running processes, you can navigate to ‘STATUS’ from the
main menu and then following the top menu ‘Processes View’ can be found.
 To check the status of the Stop Button, you can navigate to ‘STATUS’ from the
main menu and then following the top menu ‘Stop Button’ can be found.
Version 1-1C
Links for Parameterization category:

 To edit the boot.ini options, you can navigate to ‘OCPP’ from the main menu and
then following the top menu ‘BOOT’ can be found.
 To edit the OCPP configuration, you can navigate to ‘OCPP’ from the main menu.
 To edit the GUI visibility options, you can navigate to ‘GUI’ from the main menu.
 To edit the Ethernet IP address, you can navigate to ‘NETWORK’ from the main
menu and then following the top menu ‘Ethernet Configuration’ can be found.
 To edit the SIM configuration, you can navigate to ‘NETWORK’ from the main
menu and then following the top menu ‘SIM Configuration’ can be found.
‘PASS’ found on the main menu, is used to change the username and password for this
web interface.
Version 1-1C
6.2. Diagnosis
There are currently three-diagnosis options for the charging station.
SIM Signal
Check the strength of the connection using the GSM modem as connection method to the
backend server.
Location:
Click on ‘NETWORK’ from the main menu and following the top menu click on ‘SIM
Signal’.
There are three possible views for the signal webpage, whether the modem is turned off
(example shown in Figure 32), whether the modem is not connected by GSM, and when
the modem is turned on and there exists a GSM connection.
Figure 32: Example of SIM Signal webpage
Processes View
Show the status of the critical processes for the charging station to work correctly. For
each line of process there are two options ‘Running’ or ‘Not Running’.
Location:
Click on ‘STATUS’ from the main menu and following the top menu click on ‘Processes
View’.
Figure 33 is an example of the webpage, note that the webpage automatically refreshes
and has a timestamp.
Version 1-1C
Figure 33: Example of Process View webpage
Stop Button
Show whether the Stop button is currently clicked.
Location:
Click on ‘STATUS’ from the main menu and following the top menu click on ‘Stop Button’.
There are two possible options ‘PRESSED’ or ‘OK’. This feature is important to
troubleshoot if the charging station stops being able to charge a vehicle. It is also important
to note at not all Charging Stations have the Stop button feature, if so the webpage will be
disabled.
Attention
Attention
The option ‘Reset Stop Button’ will force a restart within the inner
hardware of the charging station to reset the Stop Button, it is important
to do a reset only when the charging station is idle.
Figure 34 is an example of the webpage, please note there is also a ‘Reset Stop Button’,
this allows to reset the hardware stack, please do this only when there are no cars plugged
in. This feature is optional and many not be present in all Charging Stations.
Version 1-1C
Figure 34: Example of Stop Button webpage
Version 1-1C
6.3. Parameterization
BOOT
Used to set up the main running parameters for the charging station. They are required to
be inserted manually. Click ‘Save Configuration’ when all parameters are typed.
Location:
Click on ‘OCPP’ from the main menu and following the top menu click on ‘BOOT’.
Figure 35 is an example of the webpage, please not that not all options are editable. When
some has been edited from the original configuration, it is marked with a light-blue
background.
Figure 35: Example of BOOT Configuration webpage
Version 1-1C
OCPP
Used to set up the OCPP parameters for the charging station. They are required to be
inserted manually. Click ‘Save Configuration’ when all parameters are typed.
Location:
Click on ‘OCPP’ from the main menu.
Figure 36 is an example of the webpage, there is also present a comment next to each
option.
Figure 36: Example of OCPP Configuration webpage
Version 1-1C
GUI
Used to select what to view or hide in the GUI of the charging station.
Location:
Click on ‘GUI’ from the main menu.
Figure 37 is an example of the webpage, please note that the options for each feature is
either ‘true’ or ‘false’ selectable from a dropdown menu.
Figure 37: Example of GUI Configuration webpage
Ethernet Configuration
Used to select between ‘dhcp’ (automatic) or manual IP configuration for the cabled
backend connection.
Location:
Click on ‘NETWORK’ from the main menu and following the top menu click on ‘Ethernet
Configuration’.
Figure 38 is an example of the webpage, please write only number and ‘.’ in the input fields
otherwise a wrong configuration could be loaded.
Version 1-1C
Figure 38: Example of Ethernet Configuration webpage
Version 1-1C
SIM Configuration
Used to setup the connectivity to the backend through the GSM modem incorporated in
the charging station.
Location:
Click on ‘NETWORK’ from the main menu and following the top menu click on ‘SIM
Configuration’.
Figure 39 is an example of the webpage, please write the PIN of the SIM card and the
APN of the SIM, which will be used to connect to the network, make sure the PIN is only
inserted if there is one.
Figure 39: Example of SIM Configuration webpage
Password Configuration
Used to change the password to access the web interface. Credentials should be changed
after first login.
Location:
Click on ‘PASS’ from the main menu.
Figure 40: Example of the Password Configuration webpage
Version 1-1C
7 Error description and removal Page 47 of 57
7. Error description and removal

Attention
Attention
Observe all hazard warnings in chapter 1.3
Error Description Possible error cause Troubleshooting

Display stays dark No power supply Check if circuit breakers are
switched on
Power stack cannot be The circuit breaker (-QB1, Turn on the circuit breaker
turned on -FB2) of the power stack is
switched off
No communication to the No connection via Ethernet or Check connection of the Ethernet
backend mobile network network (-XF1) or/and antenna
(-TF1)
Boot the charging station in

diagnostics mode and use the
diagnostic tool for further fault
localization
No charge possible Error in the configuration of the Boot the charging station in
charging station diagnostics mode and use the
diagnostic tool for further fault
localization
Table 15: Error description and troubleshooting
Version 1-1C
Page 48 of 57 8 Maintenance
8. Maintenance
Attention
Attention
Observe all hazard warnings in chapter 1.3
8.1. Overview of maintenance work

For the safe operation of the charging station, regular maintenance or control of the safety
equipment is required. All the points listed below are considered mandatory and must be
carried out by the operator of the switchgear at the intervals described.
Table 16 gives an overview of the intended maintenance work. Depending on the
individual conditions of use of the control cabinet, maintenance work may still be
necessary so that the list cannot be considered complete.
Maintenance work Execution Interval

Charging cable set Replacement of the complete charging cable set After 10000
charging
cycles
Residual current devices Function test of residual current circuit breaker Every 6
months
Main switch, voltage Verify the correct function Yearly
release switch
With the charging station switched off, check the Yearly
Verification of protective resistance between the ground of the supply plug
measures and all externally accessible, non-insulated cabinet
parts (housing, add-on parts, screws)
Check for cleanliness and Check if the interior of the control cabinet is clean Yearly
condensation and has no traces of condensation.
Screw Random or complete testing of tightening torques at Yearly
terminals and mechanical screw connections.
Overvoltage protection Check the surge arrester for full function Yearly
Ventilation filters Changing the filter mats Yearly
Level of cooling liquid Check the cooling liquid level (fill level indicator) Yearly
Concentration of cooling Check the concentration (test with refractometer) of Yearly
liquid the coolant liquid.
If the concentration is outside the required range, this
can be remedied by adding coolant concentrate
(concentration too low) or distilled water
(concentration too high).
pH of cooling liquid Check the pH (optimal value - pH between 8…9) of Yearly
the coolant liquid.
If the pH is below pH 7.7, replace the coolant liquid.
In this case, no complete replacement is necessary,
the change of the majority is sufficient to ensure
protection again.
Table 16: Periodic maintenance work
Version 1-1C
8 Maintenance Page 49 of 57
8.2. Replacing a hypercharger power-stack

Figure 41 shows the order of steps for changing a stack. To install the new stack perform
the steps in reverse order.
1 2 3 4 5
Open left side Remove acrylic Remove acrylic Remove the strives Open right
door glass cover glass cover side door
(upper side) (lower side)
6 7 8 9
Remove Disconnect Remove screws Pull out stack and remove.

screws signal connector supply and output Attention! Use a lifting tool for
terminal stack the replacement
Figure 41: Replacing a Power-Stack
Attention
A Power Stack weights up to 95kg. Use a lifting tool for the replacement.
Version 1-1C
Page 50 of 57 8 Maintenance
8.3. Cooling unit for cooled charging cable (optional)

If an active cooled Cable is used (see 3.6) the cooling unit for cooled charging cable is
needed.
C
E
A
F
B
Figure 42: Cooling unit for cooled charging cable (option)
A Status LEDs
B connection cooling liquid
C electric connection of the cooling unit
D filler neck
E fill level indicator
F cooling fans
To facilitate the electrical installation of the hypercharger, the cooling unit can be removed
during grid connection (see 5.4)
Version 1-1C
8 Maintenance Page 51 of 57
Cooling liquid
The coolant to use is ‘innovatek Protect PRO Konzentrat’ from innovatek OS GmbH. The
coolant must be diluted before filling with drinking water or distilled water depending on the
desired antifreeze protection (see Table 17).
Vol.- % innovatek antifreeze °C

Protect PRO
20 - 9,0
25 - 12,3
30 - 16,1
35 - 20,4
40 - 25,2
45 - 30,8
50 - 37,6
55 - 45,4
58 - 51,0
Table 17: Relation frost protection to dilution ratio
For reasons of corrosion protection, the application concentration of 25% (V/V) ‘innovatek
Protect PRO Konzentrat’ should not be undercut. This corresponds to a frost protection of -
9°C. At concentrations of less than 20% (V/V) ‘innovatek Protect PRO Konzentrat’ there is
a risk of corrosion due to under-inhibition.
With an addition of more than 58% by volume of ‘innovatek Protect PRO Konzentrat’ the
frost and corrosion protection deteriorates.
When filling the system, make sure that there are no air cushions in the cooling system
that reduce the cooling capacity.
Version 1-1C
Page 52 of 57 9 Technical specifications
9. Technical specifications
General technical data:
Parameter Nominal value

Degree of protection IP54
Mounting Indoors and outdoors
Humidity transport or storage range 0 – 95% rel. (not fogging)
Humidity operational range 0 – 95% rel.
Pollution degree pollution degree class 3
Storage temperature range -40°C – +55°C
Operating temperature range -30°C – +40°C (+55°C with derating)
Table 18: Technical data (general)
Type Wide [mm] Large [mm] Height [mm] Weight [kg]

HYC_075 854 420 2235 300
HYC_150 854 420 2235 400
HYC_225 854 732 2235 550
HYC_300 854 732 2235 650
Table 19: Mechanical data
Electrical connection data depending on the configuration:
HYC_075

Operating voltage 400Vac +N +PE (±10%)
Frequency 50Hz (±5%)
Nominal current max. 125A
Maximum protection (backup) 200A gG
Connection terminals cross section connecting bolt 12mm
Rated peak withstand current Ipk 10kA (peak)
Rated short-time withstand current Icw 4kA (rms)
Table 20: Electrical connection for HYC_075
HYC_150

Connection terminals cross section connecting bolt 12mm
Version 1-1C
9 Technical specifications Page 53 of 57

HYC_225

Connection terminals cross section connecting bolt 2x12mm
HYC_300

Connection terminals cross section connecting bolt 2x12mm
Version 1-1C
Page 54 of 57 10 Declaration of Conformity
10. Declaration of Conformity
Version 1-1C
10 Declaration of Conformity Page 55 of 57
Version 1-1C
Page 56 of 57 10 Declaration of Conformity

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hypercharger - Operation Instructions and Installation Guide

Operation Instructions and

hypercharger 75kW – 300kW

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Operation Instructions and

Original English version

© 2018 alpitronic S.r.l.

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1 Safety instructions Page 1 of 57

1.1. Designated use

The charging station is designed for a stationary installation in an

For the connection between the electric vehicle supply equipment

No adapters may be used which are not approved by the vehicle

Depending on a socket or vehicle coupling the hypercharger may only

1.3. Safety instructions for installation and maintenance

Disregards from these instructions can lead to serious or fatal personal

Page 2 of 57 1 Safety instructions

Installation and maintenance of the hypercharger ultra-fast charging

Warning of hazardous electrical voltage

Inside the hypercharger cabinet, hazardous electrical voltages are

Only hypercharger certified technicians are permitted to install,

Some cabinet internal components of the hypercharger like power stack

Prior to performing disassembly, repair or replacement of components

Please take care when assembling and disassembling components that

1 Safety instructions Page 3 of 57

Pushing the (optionally installed) Stop button (see Fehler!

Page 4 of 57 1 Safety instructions

Modell: HYC_075 / HYC_150 SERIAL NR: 18BZ00001

Figure 1: Example of Nameplate for hypercharger

2 Transport, storage, unpacking and handling Page 5 of 57

2. Transport, storage, unpacking and handling

Type W [mm] D [mm] H [mm]

2.2. Transport, handling and storage

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Figure 2: Vertical and horizontal transport with pallet truck or forklift

Figure 3: Crane eyelets on top of the packaging

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The hypercharger must be stored in its original packaging in a dry

Type Weight Weight Threat size

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Unpacking the hypercharger

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3.1. Exterior view

Figure 5: Elements of the charging station

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3.2. Site Configuration

A mechanical ramming protection with sufficient stability should be

Figure 6: Recommended distances for site configuration

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Type W1 [mm] D1 [mm] D2 [mm] D3[mm] L [mm]

To allow easy replacement of the power-stacks, a clearance of at least 110cm must be

3.3. Cable reach

Figure 7: Cable reach for the two DC outlets of the hypercharger

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3.4. Opening of the hypercharger

2° open door on the right

3° open door in the middle

1° open door on the left

Figure 8: Order for opening the hypercharger

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3.5. Internal view

3.5.1. HYC_075 and HYC_150 internal view