Alpitronic GmbH HYC50 Alpitronic Hypercharger Instruction Manual

: June 15, 2024
: Alpitronic GmbH

Table of Contents

HYC50 Alpitronic Hypercharger
Specifications
Product Usage Instructions
1. Intended use
2. User
3. Safety instructions for installation and maintenance
4. Product description
4.1 Colors HYC_50
4.2 Credit card terminal
- FAQ
Q: What is the power output of the hypercharger HYC_50?
Q: Can the hypercharger HYC_50 be used with all electric
Q: How do I make payments for charging services?

HYC50 Alpitronic Hypercharger

Specifications

Product Name: hypercharger HYC_50

Power Output: 50 kW

Product Type: Fast charging system for electric
vehicles

Hardware Version: 5.6

Manufacturer: alpitronic GmbH

Manufacturer Address: Bozner Boden Mitterweg,
33, 39100 Bozen (BZ), ITALY

Manufacturer Contact:

Tel.: +39 0471 096 450
Fax: +39 0471 096 451
Homepage: http://www.hypercharger.it
Email: info@hypercharger.it

Product Usage Instructions

1. Intended use

The hypercharger HYC_50 is designed to provide fast charging for
electric vehicles. It is intended for use by electric vehicle
owners who require quick and efficient charging.

2. User

The user of the hypercharger HYC_50 should be familiar with
electric vehicle charging protocols and safety precautions. It is
recommended to read and understand the operating and installation
instructions before using the product.

3. Safety instructions for installation and maintenance

Prior to installation and maintenance of the hypercharger
HYC_50, it is important to follow these safety instructions:

Ensure the power supply is turned off before starting any
installation or maintenance procedures.
Only qualified personnel should perform the installation and
maintenance tasks.
Do not modify or tamper with any components of the hypercharger
HYC_50 without authorization from alpitronic GmbH.
Observe all local electrical and safety regulations during
installation.

4. Product description

The hypercharger HYC_50 is a fast charging system for electric
vehicles. It is capable of delivering up to 50 kW of power to
quickly charge compatible electric vehicles. The product features
include:

High power output for rapid charging
Designed for compatibility with electric vehicles
Easy-to-use interface for convenient charging
Built-in safety features to protect the vehicle and
charger

4.1 Colors HYC_50

The hypercharger HYC_50 is available in multiple colors to suit
personal preferences and aesthetic requirements. Please refer to
the product catalog or contact alpitronic GmbH for available color
options.

4.2 Credit card terminal

The hypercharger HYC_50 is equipped with a credit card terminal
for convenient payment processing. Users can easily make payments
for charging services using their credit cards. Please follow the
on-screen instructions to complete the payment process.

FAQ

Q: What is the power output of the hypercharger HYC_50?

A: The hypercharger HYC_50 has a power output of 50 kW, allowing
for fast charging of electric vehicles.

Q: Can the hypercharger HYC_50 be used with all electric

vehicles?

A: The hypercharger HYC_50 is designed for compatibility with
electric vehicles. However, it is recommended to consult the
vehicle manufacturer’s specifications to ensure compatibility.

Q: How do I make payments for charging services?

A: The hypercharger HYC_50 is equipped with a credit card
terminal. Simply follow the on-screen instructions to complete the
payment process using your credit card.

HYC_50 Operation and Installation Guide Hardware Version 1-2
Operating and Installation Guide
Hardware
hypercharger HYC_50 (50 kW)
Fast charging system for electric vehicles
for HW-Version 5.6
All rights reserved. Reproduction of this document, in whole or in part, is only permitted with the permission of alpitronic GmbH.

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HYC_50 Operation and Installation Guide Hardware
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Content

HYC_50 Operating and installation instructions

Version
Version 1-2 the operating and installation instructions, September 2022

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 support@hypercharger.it. 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

Manufacturer

alpitronic GmbH

Bozner Boden Mitterweg, 33

39100 Bozen (BZ)

ITALY

Tel.:

+39 0471 096 450

Fax:

+39 0471 096 451

Homepage: http://www.hypercharger.it

E-Mail:

info@hypercharger.it

Service

alpitronic GmbH

Bozner Boden Mitterweg, 33

39100 Bozen (BZ)

ITALY

Tel.:

+39 0471 096 333

Fax:

+39 0471 096 451

Homepage: http://www.hypercharger.it

E-Mail:

support@hypercharger.it

Version history

Version Date

1-1A

December 2021

1-2

September 2022

Author
Ch. Leimegger
Ch. Leimegger Dr.-Ing. M. Hörter M. Hofer A. Benetti

Description First version
Extensive. Additions and adjustments

HYC_50 Operation and Installation Guide Hardware
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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. 4.1.2. 4.1.3. 4.1.4. 4.1.5.

Mounting the Stand ……………………………………………………………………………..27 Charging cable lengths…………………………………………………………………………28 Location selection ……………………………………………………………………………….29 Positioning of mounting frame HYC_50…………………………………………………..31 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. 4.2.2. 4.2.3.

Circuit diagram HYC_50……………………………………………………………………….40 Connecting the mains cables ………………………………………………………………..41 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. 6.1.2. 6.1.3.

Authentication …………………………………………………………………………………….47 Charging plug selection………………………………………………………………………..51 Plugging in the charging cable ………………………………………………………………53

6.2. During the charging process………………………………………………………………………..54

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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 6.4.2 6.4.3 6.4.4 6.4.5

Authentication failed ……………………………………………………………………………….62 Charging plug defective …………………………………………………………………………..63 Error during communication setup …………………………………………………………….64 Connector locking failed…………………………………………………………………………..65 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

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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
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HYC_50 Operation and Installation Guide Hardware Version 1-2 Content
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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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/ threephase 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 highpower 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.

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HYC_50 Operation and Installation Guide Hardware
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1.3. Safety instructions for installation and maintenance
These warnings and instructions apply to all activities related to the 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 by technicians. 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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Information

Heavy weight
Please note that the unit or the individual components of the unit can be very heavy. Bruises
When assembling and disassembling components, please ensure that no persons or body parts are bruised.
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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HYC_50 Operation and Installation Guide Hardware
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2. Product description
The HYC_50 from the hypercharger product family can be equipped with the following options:

Model

DC-Power

Options Charging interfaces

HYC_50 Power-Unit with 2x 25 kW 50 kW
Table 1: Overview DC Power and Options HYC_50

1 DC charging cable 2 DC charging cable

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 0122-23:2018-03).
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)
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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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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
CCS1/2 CHAdeMO GB/T

Charging Interface

Voltage [V]

Min.

Max.

150 V DC

1.000 V DC

150 V DC

500 V DC

150 V DC

750 V DC

Table 2: Charging interfaces

Min. 6,5 A 6,5 A 6,5 A

Current [A] Max. 150 A DC 125 A DC 150 A DC

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

GB/T

N/A

GB/T

N/A

CCS1/2

N/A

CHAdeMO

Table 3: Possible combinations of charging interfaces

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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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HYC_50 Operation and Installation Guide Hardware
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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.

Typ Bau jahr HW-Revisio n Max. Gewicht (kg) Schutzart
Netzspann ung (V) Freque nz (Hz)
Max. Einga ngsstrom (A)
Lad eschni ttstelle Min.|Max. Lade strom (A) Min.|Max. Lade spa nnung (V ) Temperaturbe reich ( °C)

HYC_50

202 2

5.6

IP55

3x 2 30 (400)

50-60

CCS2

CHAdeMO

6,5 |150 6,5 |125

150 |100 0 150 |500

-30 bis +40 (bis +55 mit Derating)

SN: 100123456

IEC 61439-7

Made in Italy

alp itron ic Srl

Via d i Mezzi ai Pian i 33

I-39100 B olzano

by a lpitronic

Figure 4: Example of a type of plate without calibration conformity for HYC_50

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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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HYC_50 Operation and Installation Guide Hardware
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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
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Attention

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Before closing the service hatch, make sure that the front door is properly locked again.

2.6. Door contactor
To detect the opening of the HYC_50 front door, door contact switches are installed as standard.

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2.7. Interior view
Figure 8 shows the interior view of the HYC_50. Figure 9 shows the interior view of the front door.

Figure 8: Interior view of the HYC_50
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Figure 9: Interior view front HYC_50 (Backside)
Table 4 describes the individual components marked in the above figures:
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HYC_50 Operation and Installation Guide Hardware
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Identifier -BE1 -BE2 -EP1 -EP2 -FC1 -FC2 -FC3 -FC4 -KF1 -KF2 -KF3 -KF4 -KF5 -KF6 -KF7 -PF1 -PF2 -PH1 -PH2 -PH3 -PH4 -PH5 -QB1 -QB2 -QB3 -QB4 -SF1 -TB1 -TB2 -TB3 -XD1 -XD2 -XD3 -XD4 -XD5 -XD6 -XF1 -XF2

Description DC meter charging point left DC meter charging point right Fan interior Blower Input fuses HYC_50 (135 A) HV-PSU fuse (4 A) Output fuse charging point left Output fuse charging point right GRID Mains connection/fuse protection CTRL_CHRG charging controller POWER_UNIT AC/DC converter DC-output switchgear DC Block left DC Block right CON_FRONT control front LED-strip left LED-strip right Touch display Card reader terminal (optional position) Terminal (RFID), antenna CTRL_DISPEXT_50 Calibration law display charging point left CTRL_DISPEXT_50 Calibration law display charging point right main switch / 3P DC-relay charging point left DC- relay parallel switching relay power modules DC-relay charging circuit right Door contact HV_PSU 24V/48V auxiliary power supply PFC coil Transformer Connection terminals Mains input DC busbar for vehicle line connection XD4 (DC output left) DC busbar for vehicle line connection XD5 (DC output right) DC charging connection left (depending on configuration) DC charging connection right (depending on configuration) DC link connector Ethernet network connector (service) Ethernet network connector (client-LAN)

Table 4: Components of the HYC_50

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Information

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The Ethernet connection XF1 can be used for load management.

2.8. Additional options
2.8.1. Colors HYC_50
The HYC_50 housing is delivered in “RAL Noire 2100” as standard. The front bezel can be customized with custom branding, making the column a statement of your business.
2.8.2. Credit card terminal
alpitronic uses the COR A20 contactless reader with OPM-C60 controller from CCV Germany. Before installing the credit card terminal, the customer must conclude an agreement with a payment provider such as BS-Payone, Concardis or CCV. alpitronic then receives the CCV terminal configured on the payment provider, which is installed in the charging station. The provider’s terminal ID is transmitted by the customer to alpitronic and played on the terminal (alternatively, this can also be configured by the customer after delivery of the hypercharger). A credit card terminal provided by the customer can also be installed as long as it is one of the models mentioned above. The credit card terminal supports all common credit and bank cards, the payments made can be viewed in the backend with a time delay.

Figure 10: Contactless credit card terminal (model COR A20)
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HYC_50 Operation and Installation Guide Hardware
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3 Packaging, transport, and storage

3. Packaging, transport, and storage
3.1. Packaging
Figure 11 shows the packaging of the HYC_50, in which it is delivered.

Figure 11: Packed HYC_50
3.2. Transport, handling, and storage
The device is delivered packed on a pallet. During transport and storage, max. 4 devices (pallet with packaging) may be stacked on top of each other. Attention
The hypercharger must be stored in its original packaging in a dry environment from -40 °C to + 55 °C.
3.3. Unpacking the HYC_50
See attached Video.
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4. HYC_50 Installation and commissioning
This chapter describes the mechanical assembly and electrical installation of the HYC_50. It is recommended to assemble and install the HYC_50 according to the following steps:
– Location selection (Chapter 4.1.3) – Positioning mounting frame HYC_50 (Chapter 4.1.4) – Connection area of the HYC_50 (Chapter 4.1.6)

4.1. Mechanical installation of the HYC_50
The following figure lists the relevant components for the mechanical installation:
Attention
Before installation, compliance with all legal requirements for the installation site (e.g. tilt resistance, impact protection, frost exposure, etc.) must be checked.
Each loading outlet must be as close as possible to the car park to be served, taking into account ergonomics and mechanical impact protection.
In Norway, charging stations for electric vehicles must be located far enough away from a potentially explosive area so that charging cannot take place within the potentially explosive area.
When selecting the installation height of the charging station, please ensure that the plug holder of the charging station is at a height above the ground in the range of 0.5 m to 1.5 m. For barrier-free installation, the height specifications in Figure 15 must be observed.

4.1.1. Mounting the Stand
The base of the HYC_50 can be fixed to the ground via 4 bolts M12 (see Figure 12). For this purpose, own foundation bases are optionally offered.
However, the installation can also be carried out on any own foundation. The sufficient mechanical strength of the foundation plate must be taken into account.

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Figure 12: Mounting the Stand HYC_50
4.1.2. Charging cable lengths
In the standard configuration, the HYC_50 is equipped with a cable length of 2,7 m. If the optionally available cable management is selected, the cable length is extended to approx. 4,45 m. Figure 13 shows the operating radius (4.15m) of the cables for the two DC outputs of the HYC_50. Longer cable lengths can also be ordered as an option.

Figure 13: Cable length for the two DC outputs of the HYC_50 with cable management
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4.1.3. Location selection
When installing the HYC_50, it must be ensured that a minimum distance to possible objects around the HYC_50 is maintained in order to ensure sufficient air flow and to have enough space available for possible service or maintenance work.
Attention

The position of the HYC_50 is to be selected, taking into account the impact protection that may be required, so that possible damage due to foreseeable circumstances is avoided.

Figure 14 shows the recommended minimum clearances to be provided when selecting a location for a HYC_50.

Figure 14: Recommended minimum distances for site selection
The recommended distances are designed for convenient maintenance of the HYC_50, the minimum distances represent the absolute minimum for maintenance work, e.g. to be able to exchange a power unit. The ground conditions should be as flat and level as possible in the areas shown.
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Attention

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The legal minimum widths for escape routes must be observed in any case.
Before installation, compliance with all legal requirements for the installation site (e.g. tilt resistance, impact protection, frost exposure, etc.) must be checked.
Each charging cable must be located as close as possible to the parking space to be supplied, taking into account ergonomics and mechanical impact protection. In doing so, observe the cable radius (Figure 13)

Information

The ground conditions should be as flat and level as possible in the areas shown.

Figure 15: Installation height (barrier-free) and minimum distances for supply air and exhaust air
For an easy replacement of the modules, the suggested dimensions should be adhered to. If HYC_50 is installed in a closed or even partially closed environment, the exhaust air must
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be prevented from being reintroduced into the supply air circuit. Impairments to the air circulation can lead to a reduction in the charging station’s performance.
The minimum distances to obstacles in the supply and exhaust air areas specified in Figure 14 must be observed. If the charging pole is to be installed without barriers, the lower edge of the display must be within a range of 850 … 1050 mm above the ground. This is the case when the uppermost fastening points of the fastening frame are at a height of 1830 mm above the ground.
The necessary mounting height of the mounting frame is shown in Figure 15.
The following information comes from a publication of the German insurers on loss prevention (VdS 3471):

– No highly flammable materials should be stored in the immediate vicinity of the charging pole.
– Charging stations are not permitted in fire-hazardous premises in accordance with VdS 2033, explosion-hazardous or explosives-hazardous areas (areas with e.g. explosives or pyrotechnics) due to the existing hazards.
– The installation of a fire alarm system is recommended – where appropriate – in order to detect a fire at an early stage and to fight it in time.
– When installing in garages, the garage regulations must be taken into account. – An additional overvoltage protection device is recommended in the power supply circuit.

Attention

The outlet temperature of the charger’s cooling airflow can reach temperatures up to 75°C

4.1.4. Positioning of mounting frame HYC_50
Figure 15 shows the mounting height for the mounting frame (center of topmost mounting points) if barrier-free installation is desired.
In this case, the lower edge of the display is at a height of 1020 mm above the floor and thus the touch buttons on the display are at a height of 1020…1050 mm.
To mount the HYC_50 on the stand as shown in Table 6, first hook the catch on the top into the retaining point provided. Then screw the bottom of the unit through the holes in the housing to the stand frame or mounting frame for wall mounting.
By adjusting the screw-on points, existing wall slopes can be compensated for up to an angle of approx. ± 0.8 degrees (15 mm).
To fix the mounting plate to the wall, M6 screws anchors/dowels with a length of 65 mm are recommended. A suitable fastening system from Fischer is shown in Table 5.

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Table 5: Load Table for Fischer dowels/anchors
4.1.5. Mounting the HYC_50 4.1.5.1. Mounting preparation
Before mounting the connection cable, the strain relief suitable for the cable diameter should be selected and the cable gland should be cut off at the corresponding point of the sealing cone so that both parts can achieve their optimum functionality. The matching cable diameters are stamped on the strain reliefs so that there is no risk of confusion.
Figure 16: Cable gland
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HYC_50 Operation and Installation Guide Hardware Version 1-2 4 HYC_50 Installation and commissioning
Figure 17: Strain relief for different cable diameters
The following tools are needed for assembly: Scissors/knife to open the packaging
Cordless screwdriver
-TX10 Attachment for cordless screwdriver -TX20 Attachment for cordless screwdriver -TX30 Attachment for cordless screwdriver
Alternative to cordless screwdriver -TX10 Screwdriver -TX20 Screwdriver -TX30 Screwdriver

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4.1.6. installation of the connection cable in the cable inlet

After the connection cable has been stripped and the phases have been roughly cut off, it can be fixed in the plastic half-shell of the cable entry with the installed cable bushing using the strain relief (TX20). Before this, the cable gland must be cut off at the appropriate point for the cable diameter using scissors/knives. During installation, make sure that the sealing contour follows the existing sealing groove. The sealing cylinder points inwards (see picture).

The individual strands must be cut and stripped in the sections shown in the figure, so that contacting is possible. The length of the remaining insulation of the cable, which is inside the cable entry, must be selected so that the cable bushing still seals on it.

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Contacting with clamps: Clamps are used for contacting between the individual strands of the connection cable and the flexible cables; these should contact the two cables with each other as shown in the picture. The flexible cable is always on top. The clamp for the PE connection is attached turned 90° The orientation of the clamps for the phases is given by the ribs in the connection area. The flexible cable for the PE connection can be recognized by the fact that a cable lug is mounted at the other end.

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To protect the cables of the phases, an intermediate plastic insert is mounted above the PE connection Required tool: TX10

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The remaining cables are held in position with the help of a cable fixation. To position them more easily, you can use the two ribs (shown in red) as a guide. In this step, care must be taken that the insulation of the cables is not pinched between the plastic parts and thus damaged. Required tool: TX10
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The flexible cables must now be fed through the cutouts provided in the cover and the cover placed on the housing and fixed in place. Required tool: TX20

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The unit can now be lifted onto the column or the back plate using the assembly crane.
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As soon as the HYC_50 hangs securely on the two upper locking bolts, the cables can be routed inside the unit.

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Now the device only has to be fixed to the back plate at the marked points (TX20 and TX30), the phases have to be connected to the main switch and the PE connection to the housing.
The mounting of the touch guard finishes the mounting process.
Table 6: Assembly steps HYC_60
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4.2. Electrical installation
The dimensioning of the cables and the protective devices outside the HYC_50 must be carried out according to the local regulations and in compliance with the technical specifications of the HYC_50.
Attention
The charger is not suitable for connection to the AC system via a plug for industrial use according to IEC 60309-1 and IEC 60309-2 or for private use according to IEC 60884-1.

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4.2.1. Circuit diagram HYC_50

Figure 18 shows the circuit diagram of the HYC_50.

-XD4

DC charging cable left

-XD5

DC charging cable right

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-KF5
-BE1 Wh I/U

-XD2

-KF6

OUTLET left 2

-XD3 OUTLET right
2

-BE2 Wh I/U

-PH5

Eichrechtsdisplay CTRL _DIS PEX T_50

-FC3

EMC 1x250A

-KF4 Out package

I/U

-FC4

EMC 1x250A

2 I/U

-QB2 2

-QB3 2

-QB4 2

-KF3 PWR_UNIT

2 -TB3

2 AB Transformer

AC 22
CD

-PH4

Eichrechtsdisplay CTRL _DIS PEX T_50

CTRL_OUT IMD IMD

CTRL_PWR

-EP1
Fan interior -EP2
Blower

-XD6 2

2 AC
DC DC-Link 2

2 AC
DC
DC

-TB2 PFC_coil

-KF1
-FA1 SPD

GRID EMC

-FC1

3x150A

-TB1

HV_PSU

-FC2 3x4A

24V dc

48V dc

-KF7

CON_FRONT

-PH3

NFC

-PH2 -PH1

Credit card Terminal
TouchDisplay

-PF1 -PF2

LED left LED right

FRONT

Door contact -KF2
-SF1

CTRL_CHRG
CON_CLIENT
(option)

HYC_50

-QB1
3

3x125A

-XD1

3PH+PE

Power signals

GRID CONNECTION
Communication

Power 24V / Ethernet

Figure 18: Circuit diagram of the HYC_50

-XF1
Client ETH (RJ45)

-XF2
Ser vice ETH
(RJ45)

Eichrecht signals

Eichrecht (optional)

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4.2.2. Connecting the mains cables
The HYC_50 charging stations can be used in TT and TN-S, TN-C and TN-C-S type supply networks.
Attention

The necessary protective measures against electric shock and other country- specific requirements must be taken into account and implemented before commissioning the charging pole.

This product is designed for type A environments (interfering emissions), the immunity is equivalent to type A environments.
Depending on the mains voltage and the configuration of the HYC_50, a protective earth current of up to 300 mA may flow. This must be taken into account when designing the protective earthing and protective measures.
This product can cause a DC current > 6 mA in the protective conductor. Where a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B or B+ is allowed on the supply side of this product. An IN = 300 mA is recommended.
Any optionally connectable external signals may only be designed and connected as SELV signals.

After the HYC_50 has been mechanically installed (see Chapter 4.1), the mains cables can be screwed to the isolator at the input.

Recommended conductor cross-sections:

Model HYC_50

Power supply connections L1, L2, L3 PE (PEN)

Table 7: Recommended cross-sections

Conductor cross section 1 x 25…50 mm2 1 x 25…50 mm2

Attention

The outer diameter of the connection cable must be in the range of 24 mm and 35 mm to ensure tightness at the cable entry seal.
Diameters larger than 35 mm cannot be mechanically accommodated.

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4.2.3. Surge protection
The HYC_50 is equipped with a type 1+2+3 surge protection (3+1 circuit) as standard so that it is also suitable for a TT grid. This means that the charging pole can be installed in LPZ zone 0A. The connection to a suitable earthing system, considering country-specific legal requirements, must be ensured.
4.3. Checks before switching on for the first time
Operation of the HYC_50 must be carried out in compliance with the test and inspection instructions described below. All instructions listed below are considered binding and must be carried out by the charging station operator before initial operation.
After transport and installation, check the following points:

Testing Mechanical visual inspection Protection class Screw connections Earthing system Lightning protection for the supply cable Selectivity
Operating conditions
Contact protection Residual current device
Short-circuit resistance
Automatic power supply cutoff Low-voltage electrical installations

Execution
Mechanically sound condition of the installed unit.
After connecting the cable connections, protection class IP55 must be ensured
Partial or complete check of tightening torques on terminals and mechanical screw connections.
Check the earthing, taking into account the site-specific conditions and the applicable standards.
Check whether lightning protection is installed for the supply line in accordance with IEC 61439-2/-7 or country-specific requirements.
To ensure selectivity, make sure that series-connected overcurrent or residual current protective devices only trip the device that is located directly upstream of the fault location. The test shall be carried out on the basis of IEC 61439-2.
Consideration of the operating conditions at the installation site (e.g. mechanical, chemical, corrosive stress) according to IEC 61439-2 /-7 as well as deviating country-specific standards.
Check whether the contact protection has been correctly mounted after the electrical installation has been completed.
Check whether a residual current circuit breaker outside the charging station is required for operation and, if so, whether it has been installed. The test must be carried out considering the sitespecific conditions and the applicable standards.
Rated current and short-circuit strength of the main busbar system considering the upstream protective device according to IEC 61439-2 /-7
The requirements of IEC 60364-4-41, section 411 must be fulfilled.
The requirements of IEC 60364-7-722 must be fulfilled.

Table 8: Checks before commissioning

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4.4. Commissioning protocol
During commissioning, the following protocol can be used, which contains the most important checkpoints:
Masterdata:

Customer Customer Column ID (EVSE-ID) Column serial number Maximum input power available at the site (kW) LoadManagement available
Locking cylinder

Yes

Manufacturer/Model:

alpitronic Customer, description:

Location type Column address GPS coordinates Installation company Name technician Date of commissioning

public private

latitude:

longitude:

Existing charging outlets (please tick):

CCS2_150A CHAdeMO_125A GB/T CCS1

1 2

Checks before first switch-on:

Check External visual inspection of the charging pole (damage, defects, protection class) Checking the stability
Is the charging pole accessible?
Checking the cable connections
Check of the fuses
Visual inspection of the screw connections (sealing wax present?) Remove and reinsert SIM cards
Is the interior of the charging pole clean and free

Executed

Result OK deficient
OK deficient OK deficient OK deficient OK deficient OK deficient
OK deficient OK deficient

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of traces of condensation? Check the air and creepage distances Check the filter mats Mains voltage correct? Functional check of the electrical protective devices Earthing system complete? Equipotential bonding connections complete?
Possible remarks:

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OK deficient

Checks at first switch-on:
Check Checking fan noise Functional check of the RFID reader Functional check of the screen touch function Functional check of the screen Functional check of the LED strips in the front
Possible remarks:

Executed

Result OK deficient OK deficient OK deficient OK deficient OK deficient

Charging tests must be carried out for each individual charging point:

Charging

Peak-Power

test

Charging

point 1

Charging

point 2 (if

available)

Charged energy

Executed

Result OK deficient OK deficient

Possible remarks:

The following photos are to be enclosed: Front and closing hatch each closed and open Type plate (badge outside on the lower edge of the HYC_50) CTRL_CHRG with identifiable connections Type plate (badge outside at the bottom edge of the hypercharger) Cable connection area with recognizable connections Location photo

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Test result: We confirm that the charging device complies with the applicable standards. In accordance with generally recognised technical rules, the safe use of the charging
device is ensured when it is used as intended
Please send the following commissioning report including photo documentation to the following e-mail address: support@hypercharger.it.
If you have any problems of any kind, please feel free to contact our hypercharger support team at any time: +39 0471 096 333
Date, Signature:

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HYC_50 Operation and Installation Guide Hardware
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5 Diagnosis and parameterization

5. Diagnosis and parameterization
After successful mechanical and electrical installation of the HYC_50, the correct function of the device can be checked with a diagnostic and parameterization tool. The diagnostic web interface can be loaded via any browser with a standard IP address, see Table 9:

Default IP address Table 9: Default IP address of the HYC_50

192.168.1.100

More information about the user interface is given in the software part of the HYC_50 operating and installation manual.

HYC_50 Operation and Installation Guide Hardware Version 1-2 6 Operation of the HYC_50
6. Operation of the HYC_50
6.1. Starting the charging process
6.1.1. Authentication
To be able to start a loading process, you must first authenticate yourself.

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Figure 19: Authentication
There are several ways to authenticate yourself at the charging station: Directly at the charging station:
– NFC1 card: Hold your user card against the RFID reader, which is located to the left of the screen (“contactless” symbol). If the charging station has a credit card terminal, the RFID reader is located to the left of the screen (see Figure 5).
– Giro-e: If the operator supports this option, you can authenticate yourself by holding your Giro-e card up to the RFID reader.
– Credit card: If a credit card terminal is available, you can authenticate via credit card by holding it up to the credit card reader below the screen.
1 NFC = “Near Field Communication”
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HYC_50 Operation and Installation Guide Hardware
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6 Operation of the HYC_50

About the backend system:
– Backend: The backend system interacts with the connected charging station via the “Remote Start Transaction”, which is regulated by the OCPP protocol. This can be used to start and stop charging processes, among other things.
– App: If provided by the operator, start the operator app that is connected to the charging pole via the backend system and follow the instructions on your smart device.
About the vehicle:
– Auto charge: If the operator offers this option, authentication can also take place directly via the vehicle in the form of “auto charge”. In this case, the vehicle is identified via the (VID2 /EVCCID3) as soon as the connection has been established via the charging cable.
– Plug & Charge: Insert the charging plug into the vehicle. As soon as the vehicle is connected, it automatically authenticates itself on behalf of the driver at the charging station (using EMAID4), among other things, by sending a digital certificate to the back end.

Figure 20: Overview of the authentication options
2 VID = “Vehicle Identification Device” 3 EVCCID = “Electric Vehicle Communication Controller Identifier” 4 EMAID = “E-Mobility Identifier Account”
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HYC_50 Operation and Installation Guide Hardware Version 1-2 6 Operation of the HYC_50
The following display appears during the authentication process:

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Figure 21: Authentication process

Information

Detailed user guidance for the entire charging process is displayed directly on the charging pole screen depending on the selected authentication medium and charging cable. An overview of the user guidance per authentication option can be found in Figure 22.
If the charging station is running in kiosk mode, no authentication is required. In this case you can directly start a new session by pressing the button below the “New Session” text on the screen.

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6.1.2. Charging plug selection
Now select the charging plug with which you want to charge your vehicle. Navigation is performed by touching the respective controls on the touchscreen.

Figure 23: Charging plug selection

Information

Depending on the configuration of the charging pole, other symbols may be displayed because other charging plugs are installed.
When the connectors are free, the corresponding LED strips light up green.
To access the language selection, press the screen at the very bottom in the middle.

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6.1.3. Plugging in the charging cable
After you have selected the type of charging cable, the display will prompt you to plug the corresponding charging cable into the designated socket on your vehicle.
Information
The corresponding LED strip flashes blue as soon as the charging cable can be plugged in. As soon as the charging process has started, it stops flashing and remains solid blue.

Figure 25: Plugging in the charging cable
Information For CHAdeMO cables, make sure that they lock correctly.
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6 Operation of the HYC_50

While the charging station is connecting to your vehicle, the following display appears:

Figure 26: Initializing
6.2. During the charging process 6.2.1. Charging overview
Now an overview of the active loading process appears, which displays the following information:
· Current state of charge (in % and kW) · Voltage (V) · Charging current (A) · Already charged energy (kWh) · Charging time (hh:mm:ss)
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Figure 27: Overview of charging process
If you select the “Lock” menu item, the display is locked. If you want to get additional information about the charging process, tap on the menu item “Details”, an overview including charging curve will appear in the following.
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Figure 28: Detailed loading overview

Information

Note that the display information may vary from operator to operator. Certain charging station operators hide this information. In this case, the charging status can be checked in the vehicle.

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It is possible to charge two vehicles at the same time. If a vehicle is already charging, you can select the free charging cable after you have successfully authenticated yourself.

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As soon as both vehicles are charging in parallel, the following overview appears:

Figure 30: Charging overview with two active charging processes
To access the respective loading overview, click on the corresponding “Details” menu item.
6.3. Stop charging process 6.3.1. Wake screen
After a certain time, the screen saver activates. To return to the loading overview, tap the touchscreen. 6.3.2. Stop charging In the lower section of the charging overview, you have the option of stopping the charging process at any time by pressing “Stop”.
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You must authenticate yourself again to cancel the charge.

Figure 32: Authentication to stop charging process

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Once you are authorized to stop charging, you will be prompted to unplug the charging cable from the vehicle. Plug it back in properly to the charging station’s designated cable holder.

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6.4 Procedure for error messages
6.4.1 Authentication failed

HYC_50 Operation and Installation Guide Hardware
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6.4 Procedure for error messages

Figure 35: Authentication failed
If this error message appears, try the authentication process again.
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HYC_50 Operation and Installation Guide Hardware Version 1-2 6.4 Procedure for error messages
6.4.2 Charging plug defective

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Figure 36: Charging plug defective
When this message appears, the operator has already been informed about the defect and will rectify the fault as soon as possible. In the meantime, switch to another charging plug if possible.
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6.4.3 Error during communication setup

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6.4 Procedure for error messages

Figure 37: Error during communication setup
When this error message appears, the vehicle was unable to connect to the charging pole. Try to start a charging process again. If this does not work, try driving the vehicle a few meters forwards and backwards to reset the charging technology and wake it up from a possible standby.
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HYC_50 Operation and Installation Guide Hardware Version 1-2 6.4 Procedure for error messages
6.4.4 Connector locking failed

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Figure 38: Connector locking failed
When this message appears, the connector could not be locked correctly. In this case, the plug could not be locked correctly. Hold the cable to the socket with your hand until you hear the locking mechanism of the car and the charging process is started.
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6.4.5 The vehicle signals an error

HYC_50 Operation and Installation Guide Hardware
Version 1-2
6.4 Procedure for error messages

Figure 39: Vehicle error
If this message appears, the car signals a charging error. Try to start a charging process again. If this does not work, try driving the car a few meters forwards and backwards to wake it up from a possible standby. Information
If you have any further questions or problems, please contact the column operator!
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HYC_50 Operation and Installation Guide Hardware Version 1-2 7 Fault description and correction
7. Fault description and correction
Attention
Observe all hazard warnings in Chapter 1

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Failure description
The display remains black The power level cannot be switched on
No communication to the backend

Possible cause
No power supply
The circuit breaker (-QB1) is switched off No connection via Ethernet or mobile network

Troubleshooting Switch on the circuit breaker Switch on the circuit breaker
Check the connection of the Ethernet network (-XF2).

Charging not possible

Error in the configuration of the charging station

Start the charging station in diagnostic mode and use the diagnostic tool for further fault localisation.
Start the charging station in diagnostic mode and use the diagnostic tool for further fault localisation.

Table 10: Fault description and correction

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8. Maintenance
Attention

HYC_50 Operation and Installation Guide Hardware
Version 1-2
8 Maintenance

Observe all hazard warnings in Chapter 1

8.1. Overview of the maintenance work

Regular maintenance or inspection of the safety equipment is required for safe operation of the charging station. All items listed below are considered mandatory and must be carried out by the switchgear operator at the intervals described. Table 11 provides an overview of the scheduled maintenance work. Depending on the individual operating conditions of the HYC_50, further maintenance work may be required, or maintenance intervals may be shortened. Therefore, the list should not be regarded as complete.

Maintenance Charging cable set

Execute
Replacing the plug contacts or the complete charging cable set.

Plug contacts Charging cable set Main switch Checking the protective measures
Check for cleanliness and condensation
Screw
Ventilation filter

Periodically check the plug contacts for contamination or traces of burns.
Check for correct function
With the charging station switched off, check the resistance between the earth of the supply and all externally accessible, non-insulated cabinet parts (housing, attachments, screws).
Check that the interior of the HYC_50 is clean and has no traces of condensation. Check the plug holders. Check seals for damage and correct position.
Random or complete testing of tightening torques on terminals and mechanical screw connections.
Replacing the air filter inserts.

Table 11: Regular maintenance work

Interval after 10000 charging cycles Half-yearly yearly yearly
yearly
yearly yearly

8.2. Function test of the main switch
To check the main switch for function, it must be turned from position On to position Off. The secondary side must be tested voltage-free.

HYC_50 Operation and Installation Guide Hardware Version 1-2
8 Maintenance

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Figure 40: Main switch with connected cables
8.3. Review of the protective measures
For this check, it is mandatory to turn off the main switch (QB1) and have a digital multimeter ready. Attention
Switch off the main switch beforehand!
Figure 41: Digital multimeter for voltage free testing
Check the resistance between the earth of the supply and all externally accessible, noninsulated cabinet parts (housing, attachments, screws).
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HYC_50 Operation and Installation Guide Hardware
Version 1-2
8 Maintenance

8.4. Checking cleanliness and condensation
Check that the interior of the column is clean and shows no signs of condensation.

8.5. Checking the screws

Check the tightening torques on terminals and mechanical screw connections randomly or completely.

Assembly PCB Busbars

Torque 1…2,5 Nm 5 Nm

Table 12: Torque of components

Information

If you have any uncertainties regarding tightening torques, please feel free to contact our support team. support@hypercharger.it or +39 0471 1961 333

8.6. Replacing the air filter inserts
Replace the air filter inserts regularly.

HYC_50 Operation and Installation Guide Hardware Version 1-2
8 Maintenance

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Figure 43: Air filter outlet
8.7. Plug contacts charging cable set
Check that the charging cables are in perfect condition. Make sure that all cable parts (cable, connector, pins, cable sleeve, locking mechanism) are free of dirt, crushing, cracks, wear, burns or other damage. Also check that the insulation is intact and that all screws are tight.

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HYC_50 Operation and Installation Guide Hardware
Version 1-2
8 Maintenance

Figure 45: Charging plug contactors
8.8. Check overvoltage protection
Check the function display marked in the following figure. Green indicates proper function; red indicates a defect.
Figure 46: Check of overvoltage protection
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HYC_50 Operation and Installation Guide Hardware Version 1-2
9 Repair and service

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9. Repair and service
The hypercharger’s modular design makes it easy to repair defective components. Attention

Please note that any repair work on the hypercharger can exclusively be carried out by trained personnel and in compliance with the required legal and safety measures!

Please consult with hypercharger support before any repairs are made. support@hypercharger.it or +39 0471 1961 333

Observe all hazard warnings in chapter 1

Information

More information on hypercharger trainings can be requested at training@hypercharger.it.

For spare parts orders you can contact sales@hypercharger.it.

Repair instructions can be requested from the hypercharger support.

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HYC_50 Operation and Installation Guide Hardware
Version 1-2
10 Disposal

10. Disposal
Electrical and electronic equipment contains materials, components and substances that may be hazardous and present a risk to human health and the environment. Hence, the hypercharger and its components shall not be discarded together with household waste, but must be collected separately.
The hypercharger is subject to the WEEE Directive 2012/19/EU (Waste of Electrical and Electronic Equipment), which is implemented differently by EU countries. Depending on the country, distributors and/or manufacturers must register and report the exported quantities of electrical and electronic equipment and pay a fee if necessary.
Cardboard and plastic packaging must be disposed of separately. Please contact your local municipality for suitable collection points.
Information

For more information, please contact the hypercharger support or check directly with a dedicated WEEE advice center.

HYC_50 Operation and Installation Guide Hardware Version 1-2
11 Technical data

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11. Technical data
General technical data and operating conditions:

Parameter Protection class Mounting location Humidity range for operation or storage Humidity range for operation Pollution degree Storage temperature range Operating temperature range Mechanical impact resistance (IEC62262) Mounting type Accessibility Installation height Protection class Supported charging modes Max. Air flow rate HYC_50 Mechanical environmental conditions Electromechanical environmental conditions Accuracy class

Nominal value IP55 Indoor and Outdoor 0…95 % rel. (non-misting) 0…95 % rel. 4 -40 °C … +55 °C -30 °C … +40 °C (+55 °C with derating) IK10 Wallmount or Stand Without restrictions up to a maximum of 4,000 m.a.s.l. Class I (protective grounding) Mode 4 420 m3/h M1 E2 A

Table 13: Technical data

Type HYC_50

Width [mm] 520

Hight [mm] 1300

Depth [mm] 220

Weight [kg] 95 … 145 kg

Table 14: Mechanical Data

Electrical connection data HYC_50
Parameter Operating voltage Ur Frequency Rated current Ir Efficiency Backup- fuse / circuit breaker to be used (mandatory) Max. connection cross-section Permissible outer diameter of the supply line Max. Rated short-circuit current Ipk Conditional rated short-circuit withstand current Icw Contribution to the short-circuit current Overvoltage category Integrated surge protection (SPD)
Table 15: Electrical connection data HYC_50

Nominal value 3x 380…400 Vac +PE (-15%…+10%) 50 Hz (±5%) 90 A 95 % @Pr (worst case) fuse 125 A gG (gL) circuit breaker 125 A (Type B or C) 50 mm² 24…35 mm 17 kA (peak) 1,4 kA (rms) @1s
Ir OVC III Type 1+2+3

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HYC_50 Operation and Installation Guide Hardware
Version 1-2
11 Technical data

Standby power consumption

Type HYC_50

Performance level STANDBY

Display brightness 7/10
10/10

Power [W] 24.7 27.0

Table 16: Idle power dissipation at 400V according to the display brightness

Wireless connections

The radio modem of the HYC_50 supports the following frequency bands:

Frequency band WCDMA B1, B8 (UMTS900, UMTS2100) LTE FDD B1, B3, B7, B8, B20, B28 GSM 900 GSM 1800

Transmission level (max. rated power) 24 dBm 23 dBm 33 dBm 30 dBm

Table 17: Frequency bands and transmission levels of the HYC_50

Attention

Observe all hazard warnings in chapter 1

Due to the higher leakage current, a minimum protective conductor crosssection of 10 mm² CU or 16 mm² AL is required.
Dangerous residual voltages
After disconnecting the HYC_50 from the power supply, the discharge time for hazardous voltages of 5 min must be observed before removing the touch guard in the device.
This product can cause a DC current > 6 mA in the protective conductor. Where a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B or B+ is allowed on the supply side of this product. An IN = 300 mA is recommended.
During operation, increased temperatures are to be expected at the air outlets

Alpitronic GmbH HYC50 Alpitronic Hypercharger Instruction Manual

HYC50 Alpitronic Hypercharger

Specifications

Product Usage Instructions

1. Intended use

2. User

3. Safety instructions for installation and maintenance

4. Product description

4.1 Colors HYC_50

4.2 Credit card terminal

FAQ

Q: What is the power output of the hypercharger HYC_50?

Q: Can the hypercharger HYC_50 be used with all electric

Q: How do I make payments for charging services?

References

Read User Manual Online (PDF format)

Download This Manual (PDF format)

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