Alpitronic Hypercharger HYC 50 Quick start guide

HYC50 - Operation and Installation Guide
Version 2-2
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Operation and Installation Guide
hypercharger HYC50
(50 kW)
Rapid charging system for electric vehicles
for HW version 7

HYC50 - Operation and Installation Guide
Version 2-2
Contents
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HYC50 - Operation and Installation Guide
Version 2-2
Contents
All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Operation and Installation Guide
Version
Version 2-2 of the Operation and Installation Guide, 21/12/2023
English translation of original German version
© 2023 alpitronic Srl
All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of
alpitronic Srl. Information in this document is subject to change without notice.
Although the contents of this document have been carefully checked for accuracy, errors cannot be
completely ruled out. If you discover an error, please inform us via [e-mail].
Manufacturer
alpitronic Srl
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-mail: [e-mail]
Service
alpitronic Srl
Via di Mezzo ai Piani, 33
39100 Bolzano (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-Mail: [e-mail]

HYC50 - Operation and Installation Guide
Version 2-2
Contents
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Notice
Please note that all warranty claims expire if the original operating
instructions are not observed.
If changes are made to the device that are not included in the
documentation from the original manufacturer alpitronic Srl or have not
been authorised by alpitronic Srl, alpitronic Srl is no longer considered
the manufacturer of the switchgear combination, but rather the person
who made the changes.
The information contained in this document is updated regularly and
without notice to customers.
To ensure that you have the most up-to-date information, we kindly ask
you to register on our hyperdoc document platform using the link below:
https://account.hypercharger.it/register
For charging stations that have been equipped in accordance with the
applicable country-specific measurement and calibration laws, further
documentation is available on hyperdoc. It is mandatory to observe this
documentation.

HYC50 - Operation and Installation Guide
Version 2-2
Contents
All rights reserved. Reproduction of this document, even in part, is only permitted with the approval of alpitronic Srl.
Table of Contents
Table of Figures..................................................................................................................8
List of tables .....................................................................................................................10
1.Safety instructions.........................................................................................................13
1.1. Intended use..........................................................................................................13
1.2. User.......................................................................................................................13
1.2.1. Requirements for the charge point operator CPO............................................13
1.2.2. Requirements for installation, commissioning and maintenance......................14
1.3. Safety instructions for installation and maintenance...............................................14
2.Product description........................................................................................................17
2.1. Charging interfaces................................................................................................20
2.2. Exterior view ..........................................................................................................23
2.2.1. Nameplate.......................................................................................................25
2.3. Opening the HYC50...............................................................................................26
2.4. Interior view............................................................................................................28
2.5. Credit card terminal (optional)................................................................................31
3.Packaging, transportation, storage and handling...........................................................32
4.HYC50 installation and commissioning..........................................................................34
4.1. Location preparation...............................................................................................35
4.2. Mechanical installation of the pedestal...................................................................37
4.2.1. Insertion of the concrete foundation ................................................................37
4.2.2. Mounting the pedestal.....................................................................................40
4.3. Mechanical installation of the wall mount plate.......................................................42
4.4. Electrical installation...............................................................................................44
4.4.1. Circuit diagram for the HYC50.........................................................................45
4.4.2. Preparing the mains cable...............................................................................47
4.4.3. Installing the mains cable in the AC grid connection box.................................49
4.4.4. Mounting the HYC50 and connecting to the mains..........................................57
4.5. Overvoltage protection...........................................................................................67
4.6. Checks before switching on for the first time ..........................................................68
4.7. Commissioning.......................................................................................................69
5.Diagnosis and parameterisation....................................................................................71
6.Operation of the HYC50................................................................................................72
6.1. Start charging.........................................................................................................72
6.1.1. Authentication.................................................................................................72
6.1.2. Selection of charging plug...............................................................................76
6.1.3. Plug in the charging cable...............................................................................78
6.2. During the charging process...................................................................................79
6.2.1. Charging overview ..........................................................................................79
6.3. Stop charging.........................................................................................................84
6.3.1. Wake up screen..............................................................................................84
6.3.2. Charging stop..................................................................................................84
6.4. Procedure for error messages................................................................................87

HYC50 - Operation and Installation Guide
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6.4.1. Authentication failed........................................................................................87
6.4.2. Charging plug defective...................................................................................88
6.4.3. Error establishing communication....................................................................89
6.4.4. Plug lock failed................................................................................................90
6.4.5. The vehicle signals an error ............................................................................91
7.Error description and correction.....................................................................................92
8.Preventive Maintenance................................................................................................93
9.Reparation and service .................................................................................................95
10. Disposal.................................................................................................................96
11. Technical data........................................................................................................97
12. Declaration of Conformity.......................................................................................99

HYC50 - Operation and Installation Guide
Version 2-2
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Table of Figures
Figure 1: HYC50 with one DC charging cable (position 1 and 2).......................................18
Figure 2: HYC50 with two DC charging cables..................................................................18
Figure 3: Order of the charging points HYC50 ..................................................................19
Figure 4: DC power characteristics in different configurations...........................................21
Figure 5: Cable length for the two DC outputs of the HYC50 with a 4.45 m cable.............22
Figure 6: Elements of the HYC50......................................................................................23
Figure 7: External dimensions of HYC50 with pedestal incl. cable management (in mm)....24
Figure 8: External dimensions of HYC50 for wall mounting incl. cable management (in mm)...24
Figure 9: Example of a nameplate for hypercharger HYC50 (without calibration law) .......25
Figure 10: Service hatch for access to the HYC50............................................................26
Figure 11: Front door locking mechanism.........................................................................27
Figure 12: Interior view of HYC50 (frontal view)................................................................28
Figure 13: Interior view of HYC50 (lateral view)................................................................29
Figure 14: HYC50 packaging............................................................................................32
Figure 15: Recommended and mandatory minimum distances when choosing a location36
Figure 16: hypercharger concrete foundation (dimensions in cm).....................................37
Figure 17: Eyebolts for lifting and positioning the foundation.............................................38
Figure 18: HYC50 on a concrete foundation.....................................................................39
Figure 19: Positioning pedestal on foundation ..................................................................40
Figure 20: Mounting the HYC50 pedestal .........................................................................41
Figure 21: Remove the pedestal cover .............................................................................41
Figure 22: Installation height (barrier-free)........................................................................42
Figure 23: Wall template...................................................................................................43
Figure 24: Circuit diagram for the HYC50 .........................................................................45
Figure 25: Attach the AC grid connection box...................................................................49
Figure 26: Removal of cable fixation and protective cover................................................50
Figure 27: Install mains cable seal....................................................................................50
Figure 28: Correct length phases and PE conductors.......................................................51
Figure 29: Secure mains cable with strain relief................................................................52
Figure 30: Attachment of cable terminals..........................................................................53
Figure 31: Mounting of protective cover via PE cable terminal..........................................54
Figure 32: Fix phases with cable fixation...........................................................................55
Figure 33: Lead the flexible cable through the opening and fix the cover..........................56
Figure 34: Position packaged HYC50...............................................................................57
Figure 35: Unpack the HYC50..........................................................................................57
Figure 36: Mounting aid HYC50........................................................................................58
Figure 37: Use mounting aid.............................................................................................58
Figure 38: Position spacer ................................................................................................59
Figure 39: Pre-assembled adapter plate on the HYC50....................................................59
Figure 40: Suspension and cable entry HYC50.................................................................60
Figure 41: Pull off mounting aid ........................................................................................61
Figure 42: Remove stickers ..............................................................................................61
Figure 43: Insert connection cables ..................................................................................62
Figure 44: Remove adapter plate......................................................................................62
Figure 45: Insert plastic cover...........................................................................................62
Figure 46: First (right) and second (left) attachment point.................................................63
Figure 47: Fasten three phases in the main switch...........................................................64
Figure 48: Attach protective conductor..............................................................................65
Figure 49: Third attachment point.....................................................................................66
Figure 50: Attach touch protection ....................................................................................67
Figure 51: Authentication screen ......................................................................................72

HYC50 - Operation and Installation Guide
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Figure 52: Overview of authentication options ..................................................................74
Figure 53: Overview of user guidance per authentication option.......................................74
Figure 54: Display shows authentication process..............................................................75
Figure 55: Selection of charging plug................................................................................76
Figure 56: Language selection..........................................................................................77
Figure 57: Plug in the charging cable................................................................................78
Figure 58: Initialising.........................................................................................................79
Figure 59: Charging overview...........................................................................................80
Figure 60: Detailed charging overview..............................................................................81
Figure 61: Charge second vehicle.....................................................................................82
Figure 62: Charging overview with two active charging processes....................................83
Figure 63: Charging stop ..................................................................................................84
Figure 64: Authentication to end the charging session......................................................85
Figure 65: Stop charging process .....................................................................................85
Figure 66: Unplug the charging cable ...............................................................................86
Figure 67: Authentication failed.........................................................................................87
Figure 68: Charging plug defective ...................................................................................88
Figure 69: Error establishing communication ....................................................................89
Figure 70: Plug lock failed.................................................................................................90
Figure 71: Vehicle error ....................................................................................................91

HYC50 - Operation and Installation Guide
Version 2-2
Contents
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List of tables
Table 1: Charging interfaces.............................................................................................20
Table 2: Possible combinations of charging interfaces......................................................20
Table 3: Components HYC50...........................................................................................30
Table 4: HYC50 shipping weight and dimensions.............................................................32
Table 5: Circuit diagram legend for the HYC50.................................................................46
Table 6: Recommended connection cross-sections..........................................................48
Table 7: Checks before commissioning.............................................................................68
Table 8: Checks to be carried out during commissioning ..................................................70
Table 9: Default IP address of the HYC50 ........................................................................71
Table 10: Error description and correction ........................................................................92
Table 11: Annual maintenance work.................................................................................94
Table 12: Technical data (general)....................................................................................97
Table 13: Mechanical data................................................................................................97
Table 14: Electrical connection data HYC50.....................................................................98
Table 15: No-load power dissipation at 400 Vac according to display brightness..............98
Table 16: Frequency bands and transmission power of the HYC50..................................98

HYC50 - Operation and Installation Guide
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HYC50 - Operation and Installation Guide
Version 2-2
1Safety instructions
Page 13 of 102
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1. Safety instructions
This chapter contains the safety instructions that must be observed during the installation,
operation and maintenance of the hypercharger rapid charging system for electric vehicles.
Improper operation by ignoring the original operating instructions can lead to serious injuries
or damages. These safety instructions must be read carefully before installing, operating
and maintaining the device.
1.1. Intended use
The HYC50 EV rapid charging system for electricvehicles is designed for indoor and outdoor
use to perform fast charging for electric vehicles.
Warning
The DC charging station is designed for fixed installation with wall
mounting or with optional floor pedestal in a pollution degree 4
environment, and is intended for locations with unrestricted access
(operation by laypersons).
The DC supply device for electric vehicles is supplied from an AC/three-
phase network and supports charging mode 4 (protection class I).
The connection between the charging station (Electric Vehicle Supply
Equipment, EVSE) and the electric vehicle (EV) requires no additional DC
cables other than those supplied by the HYC50. The charging cable must
not be modified to extend or shorten the cable range.
No adapters may be used that are not approved by the vehicle
manufacturer. The use of Y-cables or similar devices is not permitted.
1.2. User
These original operating instructions are aimed both at the charge point operator CPO with
regard to the proper operation of the charging station and at installation and maintenance
technicians with regard to installation, commissioning and maintenance.
1.2.1. Requirements for the charge point operator CPO
The charge point operator CPO is obliged to only entrustthe proper operation of the charging
station to people with relevant basic knowledge of high-performance electrical systems and
electric vehicles and proven knowledge of these original operatinginstructions. Thefollowing
requirements apply to installation, commissioning and maintenance.

HYC50 - Operation and Installation Guide
Version 2-2
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1Safety instructions
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1.2.2. Requirements for installation, commissioning and maintenance
The installation, commissioning and maintenance of the charging stations may only be
carried out by people who have received professional qualifications in accordance with the
regulations applicable at the location of the charging station and who are familiar with the
local statutory safety standards. Furthermore, these individuals must have successfully
completed the training courses prescribed by alpitronic. More information about the
mandatory training courses is available on the website https://training.hypercharger.it/.
In addition, before carrying out any work, these original operating instructions must be
carefully read by the responsible people and strictly observed.
If you have any questions, the hypercharger support team can be reached using the contact
details given above.
1.3. Safety instructions for installation and maintenance
These warnings and instructions apply to all activities related to the installation, servicing
and maintenance of the HYC50.
Warning
Failure to follow these instructions could result in death, serious injury, or
serious property damage.
Notice
Electrostatic discharge
The HYC50 contains components and circuit boards that are sensitive to
electrostatic discharge. Sufficient ESD measures to protect the electronic
components should be taken during assembly and maintenance (e.g.
wearing a grounding wristband).

HYC50 - Operation and Installation Guide
Version 2-2
1Safety instructions
Page 15 of 102
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Danger
Danger of electrical voltage
The installation and maintenance of the HYC50 may only be carried out
with the supply voltage switched off. Before installing, dismantling,
repairing or replacing components, the HYC50 must be switched off at
the main supply (e.g. transformer box) and at the main switch of the
device. A voltage test must also be carried out to ensure that the electrical
voltage is isolated from the system. The 5 safety rules of electrical
engineering should be strictly observed.
Dangerous residual voltages (up to 1000V DC) may be present inside the
HYC50 even when all circuit breakers are off.
It is therefore important to ensure that unqualified people stay away from
the HYC50 when the doors are open and that the unloading times are
observed.
After disconnecting the HYC50 from the power supply, the discharge time
for dangerous voltages of 5 minutes must be observed before removing
the protective cover in the device.
Installation, disassembly, repair or replacement of any component of the
HYC50 may only be performed by certified technicians. The doors and
openings of the HYC50 housing must be closed and locked and all
protective covers installed after any installation, maintenance or repair
work.
Hot surface warning
Some components inside the HYC50, such as the power module, fuses
and wiring, may remain hot for a long time even after the power supply
has been disconnected.
Before dismantling, repairing or replacing components, ensure that all
components have cooled down.
If necessary, use suitable safety gloves.
Warning: Heavy weights
Please note that the device and the individual components of the device
can be very heavy.
Use suitable safety shoes and gloves.
The dedicated lifting device (see Figure 36) isrecommended for lifting the
HYC50.
Risk of crushing
Please note that there is a risk of crushing when assembling,
disassembling, repairing or replacing components.
If necessary, use suitable safety gloves.

HYC50 - Operation and Installation Guide
Version 2-2
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1Safety instructions
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In case of fire
In case of fire, the emergency off switch of the external power supply - if
available - must be pressed immediately (e.g. at petrol stations). The
corresponding information must be clearly displayed by the charge point
operator CPO. The fire must then be reported immediately to the fire
brigade. Inthe event of injuries, the emergencyservicesmust be informed
immediately. The emergency numbers must be clearly displayed by the
charge point operator CPO.
If there is no emergency stop switch, the charge point operator CPO must
immediately disconnect the charging station from the external power
supply directly at the mains connection point. It is pointed out that the
mains disconnection at the mains connection point may only be carried
out by authorized and appropriately trained personnel.
People who are present at the scene of the fire must be taken out of the
danger areaimmediately or beaskedto moveaway from the danger area.
Fire protection and fire-fighting regulations applicable at the installation
site of the charging station, as well as occupational safety regulations,
can assure that extinguishing activities can be carried out according to
the relevant specifications and only by trained people (e.g. in Germany
DIN VDE 0132 "Fire-fighting in the area of electrical systems").
Corresponding information must be clearly displayed by the charge point
operator CPO. However, it is recommended that fire-fighting be left
exclusively to trained people in any case, i.e. even in the absence of
corresponding regulations.
When fighting the fire, a sufficient safety distance of at least 2 m from the
charging station must be maintained in order to minimize the electrical
risk. Only suitable extinguishing agents for electrical devices may beused
(e.g. CO2 fire extinguishers, if necessary also water, whereby the
distance of the spray jet to the charging station must be at least 2 m in
order not to be exposed to dangerous voltage flashovers).
Notice
The main switch for switching off the device is located in the lower part of
the device (QB1: see Figure 12). Set the circuit breaker to the "0" position,
this will turn off all internal components of the HYC50.
Please note possible discharging times of the capacitors of up to 5
minutes.
Warning
For some replacement work, e.g. when replacing the cable plug holder
for the charging cable, the power supply must be switched off on the
mains side. For a detailed description, please refer to the corresponding
replacement instructions.

HYC50 - Operation and Installation Guide
Version 2-2
2Product description
Page 17 of 102
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2. Product description
The HYC50 from the hypercharger product family can be equipped with one or two DC
charging cables.
A 50 kW Power-Unit, which is divided into two separate 25 kW power outputs, is used to
supply the DC charging cable installed on the HYC50.
Depending on the expansion stage of the charging station, up to two DC charging cables
can be used at the same time, with the galvanic isolation between the network and vehicles
and between the vehicles being maintained. A power output can only power one DC
charging cable at a time. If necessary, the two power outputs can be connected in parallel
so that the maximum charging power of 50 kW is made available via a single DC charging
cable.
Notice
The concept corresponds to circuit diagram 3 according to table GG.2 of
standard E DIN EN 61851-23:2018-03 (VDE 0122-2-3:2018-03).
The HYC50 housing comes standard in "Noir 2100". The front panel can
be adapted to individual branding.

HYC50 - Operation and Installation Guide
Version 2-2
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2Product description
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The following illustrations show the available product variants of the HYC50 with one or two
DC charging cables.
Figure 1: HYC50 with one DC charging cable (position 1 and 2)
Figure 2: HYC50 with two DC charging cables

HYC50 - Operation and Installation Guide
Version 2-2
2Product description
Page 19 of 102
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Notice
The order of the charging points when looking at the front door is from left
to right as shown in the figure below.
Figure 3: Order of the charging points HYC50
Notice
Customs tariff number of the HYC50: 85044060

HYC50 - Operation and Installation Guide
Version 2-2
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2Product description
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2.1. Charging interfaces
The following charging interfaces can be selected for the HYC50 in various combinations.
Active cooling is not provided for any of the cable variants.
Charging interfaces
Charging interface
Voltage [V]
Current [A]
Min.
Max.
Min.
Max.
CCS Combo 2
150 V DC
1,000 V DC
6.5 A
150 A DC
CHAdeMO
150 V DC
500 V DC
6.5 A
125 A DC
CCS Combo 1
150 V DC
1,000 V DC
6.5 A
150 A DC
Table 1: Charging interfaces
Notice
The total power of the HYC50 is limited to a maximum current rating of
90 Arms on the AC input side.
The usable DC power of the HYC50 is limited by the maximum current of
the DC charging cable used.
The charging cables CCS1 and CCS2 can be equipped with temperature
sensors that can derate the maximum available charging current when
the defined temperature limits are reached.
Please note that CHAdeMO cables can only be operated at a maximum
altitude of 2,000 m above the sea level.
The following charging cable combinations are possible:
Charging interfaces
Charging cable 1 (left)
Charging cable 2 (right)
CCS1/2
N/A
CCS1/2
CCS1/2
N/A
CCS1/2
CHAdeMO
CCS1/2
CHAdeMO
N/A
Table 2: Possible combinations of charging interfaces