Alpitronic Hypercharger HYC 50 User manual

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
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Operating and
Installation Guide
Hardware
hypercharger HYC_50
(50 kW)
Fast charging system for electric vehicles
for HW-Version 5.6

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
Content
All rights reserved. Reproduction of this document, inwhole orin part,is only permitted withthe permissionof alpitronic GmbH.

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
Content
All rights reserved. Reproduction of this document, inwhole orin part, is only permitted with the permission of alpitronic GmbH.
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HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
Content
All rights reserved. Reproduction of this document, inwhole orin part,is only permitted withthe permissionof alpitronic GmbH.
HYC_50 Operating and
installation instructions
Version
Version 1-2 the operating and installation instructions, September 2022
English original document
© 2022 alpitronic GmbH
All rights reserved. Reproduction of this document, in whole or in part, is only permitted with the
permission of alpitronic GmbH. The information in this document is subject to change without notice.
Although the content of this document has been carefully checked for accuracy, errors cannot be
completely ruled out. If you discover an error, please inform us at [e-mail]. alpitronic
GmbH accepts no responsibility for errors that may occur in this document. This document was originally
written in English. Versions in other languages are translations of the original document and alpitronic
GmbH accepts no liability for errors in translation. In case of doubt, the original English version
constitutes the reference document, the text of which is legally binding.
In no event shall alpitronic GmbH be liable for any direct, indirect, special, incidental, consequential or
other damages of any kind (including, without limitation, damages for loss of profits or loss of data)
arising out of the use of this document.
Attention
Please note that all warranty claims become void if these operating and
installation instructions are not observed.
If changes are made to the device that are not included in the evidence of
the original manufacturer alpitronic GmbH or have not been authorized and
released by alpitronic GmbH, the person concerned is considered the
manufacturer of the switchgear combination and not alpitronic GmbH.
Please note that for chargers, which were optionally and on customer
request built in conformity with the MessEG/EV, the appendix A1
("Technical documentation for the MessEG/EV") must be observed as
further documentation.

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
Content
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Manufacturer
alpitronic GmbH
Bozner Boden Mitterweg, 33
39100 Bozen (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-Mail: [email protected]
Service
alpitronic GmbH
Bozner Boden Mitterweg, 33
39100 Bozen (BZ)
ITALY
Tel.: [phone]
Fax: [phone]
Homepage: http://www.hypercharger.it
E-Mail: [email protected]
Version history
Version
Date
Author
Description
1-1A
December 2021
Ch. Leimegger
First version
1-2
September 2022
Ch. Leimegger
Dr.-Ing. M. Hörter
M. Hofer
A. Benetti
Extensive. Additions and adjustments

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
Content
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Content
Content...............................................................................................................................6
Figures ...............................................................................................................................8
Tables.................................................................................................................................9
1.Safety instructions.........................................................................................................11
1.1. Intended use..........................................................................................................11
1.2. User.......................................................................................................................11
1.3. Safety instructions for installation and maintenance...............................................12
2.Product description........................................................................................................14
2.1. Charging interfaces................................................................................................16
2.2. DC-Power unit / Power outputs..............................................................................17
2.3. Type plate..............................................................................................................18
2.4. Exterior view ..........................................................................................................19
2.5. Opening the HYC_50.............................................................................................20
2.6. Door contactor........................................................................................................21
2.7. Interior view............................................................................................................22
2.8. Additional options...................................................................................................25
2.8.1. Colors HYC_50...............................................................................................25
2.8.2. Credit card terminal.........................................................................................25
3.Packaging, transport, and storage.................................................................................26
3.1. Packaging..............................................................................................................26
3.2. Transport, handling, and storage............................................................................26
3.3. Unpacking the HYC_50..........................................................................................26
4.HYC_50 Installation and commissioning .......................................................................27
4.1. Mechanical installation of the HYC_50...................................................................27
4.1.1. Mounting the Stand.........................................................................................27
4.1.2. Charging cable lengths....................................................................................28
4.1.3. Location selection ...........................................................................................29
4.1.4. Positioning of mounting frame HYC_50...........................................................31
4.1.5. Mounting the HYC_50.....................................................................................32
4.1.5.1. Mounting preparation...............................................................................32
4.1.6. installation of the connection cable in the cable inlet.......................................34
4.2. Electrical installation...............................................................................................39
4.2.1. Circuit diagram HYC_50..................................................................................40
4.2.2. Connecting the mains cables ..........................................................................41
4.2.3. Surge protection..............................................................................................42
4.3. Checks before switching on for the first time ..........................................................42
4.4. Commissioning protocol.........................................................................................43
5.Diagnosis and parameterization....................................................................................46
6.Operation of the HYC_50..............................................................................................47
6.1. Starting the charging process.................................................................................47
6.1.1. Authentication.................................................................................................47
6.1.2. Charging plug selection...................................................................................51
6.1.3. Plugging in the charging cable ........................................................................53
6.2. During the charging process...................................................................................54

HYC_50 –Operation and Installation Guide
Hardware
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6.2.1. Charging overview ..........................................................................................54
6.3. Stop charging process............................................................................................58
6.3.1. Wake screen...................................................................................................58
6.3.2. Stop charging..................................................................................................58
6.4 Procedure for error messages................................................................................62
6.4.1 Authentication failed ...........................................................................................62
6.4.2 Charging plug defective......................................................................................63
6.4.3 Error during communication setup ......................................................................64
6.4.4 Connector locking failed......................................................................................65
6.4.5 The vehicle signals an error................................................................................66
7.Fault description and correction.....................................................................................67
8.Maintenance..................................................................................................................68
8.1. Overview of the maintenance work.........................................................................68
8.2. Function test of the main switch.............................................................................68
8.3. Review of the protective measures.........................................................................69
8.4. Checking cleanliness and condensation.................................................................70
8.5. Checking the screws..............................................................................................70
8.6. Replacing the air filter inserts.................................................................................70
8.7. Plug contacts charging cable set............................................................................71
8.8. Check overvoltage protection.................................................................................72
9.Repair and service ........................................................................................................73
10. Disposal.................................................................................................................74
11. Technical data........................................................................................................75

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
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Figures
Figure 1: HYC_50 with open front door (Example with two DC charging cables) ..............14
Figure 2: HYC_50 with two DC charging cables................................................................15
Figure 3: DC power characteristics in different configurations...........................................17
Figure 4: Example of a type of plate without calibration conformity for HYC_50................18
Figure 5: Elements of the HYC_50....................................................................................19
Figure 6: Locking lid of the HYC_50..................................................................................20
Figure 7: Front door locking mechanism...........................................................................20
Figure 8: Interior view of the HYC_50...............................................................................22
Figure 9: Interior view front HYC_50 (Backside) ...............................................................23
Figure 10: Contactless credit card terminal (model COR A20)..........................................25
Figure 11: Packed HYC_50 ..............................................................................................26
Figure 12: Mounting the Stand HYC_50 ...........................................................................28
Figure 13: Cable length for the two DC outputs of the HYC_50 with cable management..28
Figure 14: Recommended minimum distances for site selection.......................................29
Figure 15: Installation height (barrier-free) and minimum distances for supply air and exhaust
air .....................................................................................................................................30
Figure 16: Cable gland......................................................................................................32
Figure 17: Strain relief for different cable diameters..........................................................33
Figure 18: Circuit diagram of the HYC_50.........................................................................40
Figure 19: Authentication..................................................................................................47
Figure 20: Overview of the authentication options.............................................................48
Figure 21: Authentication process.....................................................................................49
Figure 22: Overview user guide per authentication option.................................................50
Figure 23: Charging plug selection....................................................................................51
Figure 24: Language selection..........................................................................................52
Figure 25: Plugging in the charging cable.........................................................................53
Figure 26: Initializing.........................................................................................................54
Figure 27: Overview of charging process..........................................................................55
Figure 28: Detailed loading overview................................................................................56
Figure 29: Load second vehicle........................................................................................57
Figure 30: Charging overview with two active charging processes....................................58
Figure 31: Stop charging...................................................................................................59
Figure 32: Authentication to stop charging process...........................................................60
Figure 33: Process charging stop......................................................................................60
Figure 34: Unplug the charging connector ........................................................................61
Figure 35: Authentication failed.........................................................................................62
Figure 36: Charging plug defective ...................................................................................63
Figure 37: Error during communication setup ...................................................................64
Figure 38: Connector locking failed...................................................................................65
Figure 39: Vehicle error ....................................................................................................66
Figure 40: Main switch with connected cables..................................................................69
Figure 41: Digital multimeter for voltage free testing .........................................................69
Figure 42: Air filter inlet.....................................................................................................70
Figure 43: Air filter outlet...................................................................................................71
Figure 44: Charging plug side view...................................................................................71
Figure 45: Charging plug contactors.................................................................................72
Figure 46: Check of overvoltage protection.......................................................................72

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
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Tables
Table 1: Overview DC Power and Options HYC_50 .........................................................14
Table 2: Charging interfaces.............................................................................................16
Table 3: Possible combinations of charging interfaces......................................................16
Table 4: Components of the HYC_50 ...............................................................................24
Table 5: Load Table for Fischer dowels/anchors...............................................................32
Table 6: Assembly steps HYC_60.....................................................................................38
Table 7: Recommended cross-sections............................................................................41
Table 8: Checks before commissioning.............................................................................42
Table 9: Default IP address of the HYC_50 ......................................................................46
Table 10: Fault description and correction ........................................................................67
Table 11: Regular maintenance work................................................................................68
Table 12: Torque of components......................................................................................70
Table 13: Technical data...................................................................................................75
Table 14: Mechanical Data ...............................................................................................75
Table 15: Electrical connection data HYC_50...................................................................75
Table 16: Idle power dissipation at 400V according to the display brightness ...................76
Table 17: Frequency bands and transmission levels of the HYC_50.................................76

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Hardware
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HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
1Safety instructions
Page 11 of 76
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1. Safety instructions
This chapter contains the safety instructions that must be observed when installing,
operating and maintaining the HYC_50 rapid charging system for electric vehicles. Improper
operation due to non-observance of the operating instructions can lead to serious injuries or
damage. These safety instructions must be read carefully before installing, operating and
maintaining the unit.
1.1. Intended use
The HYC_50 rapid charging system for electric vehicles is intended for indoor and outdoor
use to carry out rapid charging processes for electric vehicles.
Attention
The DC charging station is designed for fixed installation with
attachment to the wall or with optional stand on the floor in an
environment with a pollution degree class 4 and intended for locations
with unrestricted access (operation by laymen).
The DC supply device for electric vehicles is supplied from an AC/ three-
phase network and supports charging mode 4 (protection class I).
For the connection between the charging station (Electric Vehicle
Supply Equipment, EVSE) and the electric vehicle (EV), no other DC
cables are required apart from those supplied with the HYC_50. The
charging cable must not be modified to extend or shorten the cable
range.
Do not use adapters that are not approved by the vehicle manufacturer.
The use of Y-cables or similar devices is not permitted.
1.2. User
These operating and installation instructions are intended for people who are responsible
for the installation, operation, maintenance and servicing of the HYC_50 rapid charging
system for electric vehicles. These people should have at least a basic knowledge of high-
power electrical systems and electric vehicles. Before carrying out any work, these
instructions must be read carefully by both the operator and the technical personnel in
charge.

HYC_50 –Operation and Installation Guide
Hardware
Version 1-2
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1Safety instructions
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1.3. Safety instructions for installation and maintenance
These warningsand instructions applyto all activities related tothe installation, maintenance
and servicing of the HYC_50.
Attention
Failure to follow these instructions may result in serious or fatal injury and
severe property damage.
The installation and maintenance of the HYC_50 rapid charging system
for electric vehicles may only be carried out by qualified personnel.
Before commissioning, check that the system and all connections have
been properly installed.
Electrostatic discharge
The HYC_50 contains components and circuit boards that are sensitive
to electrostatic discharge. Sufficient ESD measures should be taken
during assembly and maintenance to protect the electronic components
(e.g. wearing a grounding arm strap).
Warning notice
Warning of dangerous electrical voltage
Installation and maintenance of the HYC_50 may only be carried out with
the supply voltage switched off. Before installing, dismantling, repairing
or replacing components, the HYC_50 must be disconnected from the
power supply and the main switch in the device must be switched off. In
addition, carry out a voltage check to ensure that the electrical voltage is
disconnected from the system.
Dangerous electrical voltages (up to 1000 VDC) can be present inside
the HYC_50, even if all isolators are switched off.
Care must therefore be taken to ensure that unqualified persons keep
away when the doors of the HYC_50 are open and the discharge time are
observed.
Installation, dismantling, repair or replacement of components of the
HYC_50 must only be carried out bytechnicians. The door of the HYC_50
enclosure must be properly closed and locked after installation,
maintenance or repair work.
Warning of hot surfaces
Some components inside the HYC_50, such as the power unit,
transformer and cables, may remain hot for a long time after the power
supply has been disconnected.
Before dismantling, repairing or replacing components, ensure that all
components have cooled down.

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Hardware
Version 1-2
1Safety instructions
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Heavy weight
Please note that the unit or the individual components of the unit can be
very heavy.
Bruises
When assemblingand disassembling components, please ensurethat no
persons or body parts are bruised.
Information
The main switch for switching off the unit is located in the lower part of
the unit (see Figure 8 and Figure 9). Set the circuit breaker to position "0",
this will switch off all internal components of the HYC_50.
Please note possible discharge times of DC link capacitors.

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Hardware
Version 1-2
Page 14 of 76
2Product description
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2. Product description
The HYC_50 from the hypercharger product family can be equipped with the following
options:
Table 1: Overview DC Power and Options HYC_50
Classification according to DIN EN 61851-23
Depending on the configuration, the DC charging station supports up to two outputs for
simultaneous operation while maintaining galvanic isolation between the mains and the
vehicles and between the vehicles themselves. The design corresponds to circuit diagram
3 according to table GG.2 of the standard E DIN EN 61851-23:2018-03 (VDE 0122-2-
3:2018-03).
The charging station does not support an optional ventilation function.
Figure 1 and Figure 2 show the HYC_50 which can be equipped with one or two DC charging
cables.
Figure 1: HYC_50 with open front door (Example with two DC charging cables)
Model
Options
DC-Power
Charging interfaces
HYC_50
Power-Unit with 2x 25 kW →50 kW
1 DC charging cable
2 DC charging cable

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Hardware
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2Product description
Page 15 of 76
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Figure 2: HYC_50 with two DC charging cables
The various possibilities and options for DC charging are described in chapters 2.1 and 0
describe.
Information
As standard, the HYC_50 enclosure is supplied in "RAL Noir 2100". The
front panel can be adapted to customized branding, making the column
a flagship for your company.
Customs tariff number of the HYC_50: 85044055

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Hardware
Version 1-2
Page 16 of 76
2Product description
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2.1. Charging interfaces
The following charging interfaces can be selected for the HYC_50 in various combinations.
Active cooling is not provided for any of the cable variants.
Charging Interface
Charging interface
Voltage [V]
Current [A]
Min.
Max.
Min.
Max.
CCS1/2
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
GB/T
150 V DC
750 V DC
6,5 A
150 A DC
Table 2: Charging interfaces
Attention
The total power of the HYC_50 is limited to a nominal current of 90 A.
Information
The CCS1 (US) and GB/T (China) options are special options for the
automotive industry.
The following combinations are possible:
Charging interfaces
Outlet 1 (right)
Outlet (left)
CCS1/2
N/A
CCS1/2
CHAdeMO
CCS1/2
CCS1/2
CCS1/2
GB/T
N/A
GB/T
N/A
CCS1/2
N/A
CHAdeMO
Table 3: Possible combinations of charging interfaces

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Hardware
Version 1-2
2Product description
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2.2. DC-Power unit / Power outputs
A power module with two 2x 25 kW power outputs are used internally to supply the DC
charging cables installed on the HYC_50. A power output can only supply one DC charging
cable at a time. The HYC_50 power outputs can be connected in parallel to increase the
power transmitted via a DC charging cable.
Information
The usable DC power of the HYC_50 is limited by the maximum current
of the DC charging cable used.
The charging cables can be equipped with temperature sensors, which
can lead to a derating of the maximum charging current provided when
defined temperature limits are reached.
Figure 3 shows the DC power characteristics with one and two HYC_50 power outputs and
different cable types (HYC_50 power stacks and different cable types (150 A GB/T, CCS1
and CCS2 cables, 125A CHAdeMO cable).
Figure 3: DC power characteristics in different configurations

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Hardware
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2Product description
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2.3. Type plate
Depending on the configuration of the charging station, the following type of plate (example)
may be on the unit.
SN:100123456
IEC 61439-7
Typ
Baujahr
Netzspannung (V)
Frequenz (Hz)
Max. Eingangsstrom (A)
Min.|Max. Ladestrom (A)
Min.|Max. Ladespannung (V)
Max. Gewicht (kg)
HW-Revision
Schutzart
Ladeschnittstelle
Temperaturbereich (°C)
HYC_50
2022
5.6
95
IP55
3x 230 (400)
50-60
90
CCS2
6,5 |150
-30 bis +40 (bis +55 mit Derating)
CHAdeMO
6,5 |125
150|1000 150|500
Made in Italy
alpitronic Srl
Via di Mezzi ai Piani 33
I-39100 Bolzano by alpitronic
®
Figure 4: Example of a type of plate without calibration conformity for HYC_50

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Version 1-2
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2.4. Exterior view
The following figure 5 shows the various elements of the unit from the outside.
Figure 5: Elements of the HYC_50
A DC charging cable 1 (depending on configuration)
B DC charging cable 2 (depending on configuration)
C Air inlet
D Air outlet
E Display / HMI
F RFID card reader (optional position if I equipped with credit card reader)
G Charging plug holder 1
H Charging plug holder 2
I RFID card reader or credit card reader (optional)
K Type plate

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2Product description
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2.5. Opening the HYC_50
The HYC_50 has a front door that can be opened via a locking lid on the left side (below the
charging plug holder). This has two locking cylinders (10/30 mm profile half cylinder).
The locking cylinder on the left (see Figure 6) is the one for alpitronic support, the customer
locking cylinder is on the left (empty on delivery).
Steps to open the inlet:
•turn the key 90° in the direction shown in Figure 6
•tilt the inlet forward and down.
Steps to close the inlet:
•insert the nose of the inlet into the opening at the bottom and
•push the inlet up into the center of the opening until it snaps into place
Figure 6: Locking lid of the HYC_50
After opening the locking lid, the front door lock can be released and the door opened.
Figure 7: Front door locking mechanism