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ZCS AZZURRO CONNEXT User Manual

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"CONNEXT" Control System
User Manual
"Connext System User Manual" of 10/01/2023 Rev. 2.2
Zucchetti Centro Sistemi S.p.A. - Green Innovation Division
Via Lungarno, 248 - 52028 Terranuova Bracciolini - Arezzo, Italy
tel. +39 055 91971 - fax. +39 055 9197515
innovation@zcscompany.com - zcs@pec.it - zcsazzurro.com
Pile Reg. IT12110P00002965 - Share Capital € 100,000.00 fully paid up
AR Company Reg. no. 03225010481 - REA AR no. 94189
ISO 9001 Certified Company - Certificate no. 9151 - CNS0 - IT-17778

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Summary of Contents for ZCS AZZURRO CONNEXT

  • Page 1 Via Lungarno, 248 - 52028 Terranuova Bracciolini - Arezzo, Italy tel. +39 055 91971 - fax. +39 055 9197515 innovation@zcscompany.com - zcs@pec.it - zcsazzurro.com Pile Reg. IT12110P00002965 - Share Capital € 100,000.00 fully paid up AR Company Reg. no. 03225010481 - REA AR no. 94189...
  • Page 2 Please check our website http://www.zcsazzurro.com for the latest version. Technical support ZCS offers full technical support and advice which can be accessed by making a direct request through the website www.zcsazzurro.com The toll-free number for Italy is: 800 72 74 64.

  • Page 3: Table Of Contents

    Configuration 4 – System with Azzurro single-phase photovoltaic inverter ......30 5.5. Configuration 5 – System with Azzurro three-phase photovoltaic inverter ......33 Systems without ZCS Azzurro inverter ......................35 6.1. Configuration 6 – System with single-phase photovoltaic production ........35 6.2.
  • Page 4 Solo documento principale. Dry contact management ............................53 8.1. Setting dry contacts from app ........................53 Access for maintenance only..........................56 9.1. Access connection for maintenance only ....................56 Technical datasheet ............................. 57 Maintenance ................................58 11.1. Troubleshooting ..............................58 11.2.
  • Page 5 Solo documento principale. Preface General information Please read this manual carefully before installation, use or maintenance. This manual contains important safety instructions that must be followed during installation and maintenance of the system. Scope This manual describes the assembly, installation, electrical connections, commissioning, maintenance and troubleshooting of the Connext system.
  • Page 6 Solo documento principale. Caution: indicates a hazardous situation which, if not resolved or avoided, could result in minor or moderate personal injury Caution Attention: indicates a potentially hazardous situation which, if not resolved or avoided, could result in damage to the system or other property Attention Note: provides important tips on correct and optimal operation of...

  • Page 7: Preliminary Safety Instructions

    Solo documento principale. 1. Preliminary safety instructions If you have problems or questions in reading and understanding the following information, please contact Zucchetti Centro Sistemi S.p.A. through the appropriate channels. Note 1.1. Safety instructions This section highlights the main safety instructions to be followed during installation and use of the equipment.
  • Page 8 Warning Do not remove the information label or tamper with the system. Otherwise, ZCS will not provide any warranty or assistance. Note Connext User Manual Rev. 2.2 10/01/2023...

  • Page 9: Symbols And Icons

    Solo documento principale. Operation Do not use the product if it has any defects, cracks, scratches or leaks, but contact your dealer or ZCS technical service. Contact with the electrical grid or the terminal of the equipment may cause electrocution or fire! Do not touch the terminal or the conductor connected to the •...
  • Page 10 Solo documento principale. Labels Figure 2 - Labels on the System Connext User Manual Rev. 2.2 10/01/2023 10/67 Identification: MD-AL-GI-00 Rev. 1.2 07.06.21 - Application: GID...

  • Page 11: Product Features

    Solo documento principale. 2. Product features 2.1. Product presentation The Connext control system is able to communicate with Azzurro electric vehicle charging stations and Azzurro photovoltaic inverters. It can also measure energy consumption, monitor systems and safety limits and control domestic loads through the use of accessory sensors and programmable contacts.

  • Page 12: Product Overview

    Solo documento principale. Figure 4 – Example of Connext system connection in a three-phase system Overall dimensions: H × W × D = 105 mm x 85 mm (with antenna installed) x 89 mm. 2.2. Product overview Connext can be installed on DIN bar (8 modules) and powered by a 230V AC mains power supply. It can be connected to Azzurro accessories, charging stations and inverters, as well as the necessary power supplies.
  • Page 13 Solo documento principale. The system has a 24-pin terminal block at the bottom for connecting the devices and accessories, a 3-pin terminal block at the top right for power supply connections, an Ethernet connector at the top, a slot for a microSD card at the top (for possible data storage), a front graphic display and a front connection for the 4G (or Ethernet) communication antenna.
  • Page 14 The “push-push” SD card slot allows the use of a microSD card with maximum capacity of 8 GB. The card is inserted and removed by simply pushing the card in. The microSD card is not on board the device and is only required for specific applications, as specified by ZCS Technical Support. Ethernet connector The Ethernet connector with two LEDs enables network connection via cable.

  • Page 15: Installation

    Solo documento principale. 3. Installation DO NOT install the charging station near flammable materials. • DO NOT install the charging station in an area where flammable or • explosive materials are stored. Danger Take into account the weight of the charging station during •...
  • Page 16 Solo documento principale. Contents of the packaging Component Connext Product documentation Table 4 – Package contents Installation tools The following tools are required for installation and electrical connections; therefore, they must be prepared before installation. Tool Function To screw and unscrew Screwdriver screws for the various connections...

  • Page 17: Installation Process

    The installation location chosen must allow easy access for normal operation and maintenance. For safety reasons, ZCS and/or its authorised partners may not perform repair/maintenance work or move the appliance from and to the ground if the devices are installed at a height of more than 180 cm.

  • Page 18: Electrical Connections

    Solo documento principale. 3.4. Electrical connections This chapter describes the electrical connections of the system. Carefully read this section before connecting the cables. All the local, regional and national regulations must be complied with during installation, repair and maintenance of the product. Before making any electrical connections, make sure there is no AC current.
  • Page 19 Solo documento principale. Cable connection procedure 1) Remove a suitable length of the protective sleeve, as shown in the figure (A: 80~100 mm B: 6~8 mm). Figure 8- Connecting AC power cables 2) Connect the AC power cable as shown the 3-pin terminal block (Figure 7). Connext User Manual Rev.

  • Page 20: Connecting To Azzurro Ev Charging Stations

    Solo documento principale. 4. Connecting to Azzurro EV charging stations Up to 8 Azzurro EV charging stations can be connected in cascade. Connect the Connext system to the first EV charging station according to the instructions given here. 1) Connect the 8-pin cable to the ports indicated as CAN port in the relevant figure using a RJ45 connector.
  • Page 21 Solo documento principale. 3) Remove a suitable length of the protective sleeve, as shown in the figure (A: 80~100 mm B: 6~8 mm). Figure 11 – Preparing the CAN bus cables 4) Connect the cables according to the table below. Pin RJ45 Cable colour Connection...
  • Page 22 Solo documento principale. 5) Connect any other wallboxes in cascade using the RJ45 connectors of the CAN ports as "in- out." Only the first wallbox is connected to the Connext system. Consult the manual of the charging station to check the firmware version installed.

  • Page 23: Systems With Zcs Azzurro Inverter

    Solo documento principale. 5. Systems with ZCS Azzurro inverter Up to 8 Azzurro photovoltaic or storage inverters can be connected in cascade. Connect the Connext system to the first inverter according to the instructions given here. To connect to hybrid, storage or photovoltaic inverters, follow the instructions in the sections below.
  • Page 24 Solo documento principale. Follow the instructions to connect the RS485 port to HYD-3000/3600/4000/5000/6000-ZSS -HP inverters. Figure 14 – Preparing RS485 cables 1) Remove a suitable length of the protective sleeve, as shown in the figure (A: 80~100 mm B: 6~8 mm). 2) Connect the 2-pole cable to the pins of the HP hybrid inverter marked “RS485”.
  • Page 25 Solo documento principale. Figure 16 - RS485 connections to single-phase hybrid inverter CAN/485m/485s Figure 17 - Connections on single-phase hybrid inverter RS485 Pin 24-pin terminal block RS485 + (Red) RS485 – (Black) Table 9 - RS485 connections to 3000SP inverter Connext User Manual Rev.

  • Page 26: Configuration 2 - System With Azzurro 3000Sp Inverter

    Solo documento principale. 5.2. Configuration 2 – System with Azzurro 3000SP inverter THE SENSOR (OR SENSORS) FOR MEASURING THE EXCHANGE MUST BE CONNECTED TO THE INVERTER ACCORDING TO THE MANUAL Figure 18 - Configuration 2 with 3000SP retrofit inverter Follow the instructions to connect the RS485 port to 3000SP inverters. 1) Remove a suitable length of the protective sleeve, as shown in the figure (A: 80~100 mm B: 6~8 mm).
  • Page 27 Solo documento principale. 2) Connect the 2-pole cable to the port of the 3000SP inverter marked “RS485”. Follow the polarity shown in the figure and the pin-out in the table. CAN/485m/485s Figure 20 - Connections on 3000SP inverter RS485 Pin 24-pin terminal block RS485 + (Red) RS485 –...

  • Page 28: Configuration 3 - System With Azzurro Three-Phase Hybrid Inverter

    Solo documento principale. 5.3. Configuration 3 – System with Azzurro three-phase hybrid inverter Figure 22 - Configuration 3 with three-phase hybrid inverter THE SENSORS OR METER FOR MEASURING THE EXCHANGE MUST BE CONNECTED TO THE INVERTER ACCORDING TO THE MANUAL Follow the instructions to connect the RS485 port to HYD-5000/6000/8000/10000/15000/20000 inverters.
  • Page 29 Solo documento principale. Figure 23 - Preparing RS485 cables 2) Connect the 2-pole cable to the port of the hybrid inverter marked “COM”. Follow the polarity shown in the figure and the pin-out in the table. Figure 24 - Connecting on COM Port for three-phase hybrid inverter COM port pin 24-pin terminal block 1 (Red)

  • Page 30: Configuration 4 - System With Azzurro Single-Phase Photovoltaic Inverter

    Solo documento principale. Figure 25 - RS485 connections with three-phase hybrid inverter 5.4. Configuration 4 – System with Azzurro single-phase photovoltaic inverter A SENSOR MUST BE MOUNTED ON THE CONNEXT SYSTEM FOR MEASURING THE EXCHANGE Figure 26 - Configuration 4 with single-phase string inverter Follow the instructions to connect the RS485 port to Azzurro single-phase photovoltaic inverters.
  • Page 31 Solo documento principale. 1) Remove a suitable length of the protective sleeve, as shown in the figure (A: 80~100 mm B: 6~8 mm). Figure 27 – Preparing RS485 cables 2) Connect the 2-pole cable to the port of the photovoltaic inverter marked “RS485”. Follow the polarity shown in the figure and the pin-out in the table.
  • Page 32 Solo documento principale. Figure 29 - RS485 connections with single-phase string inverter Figure 30 – Connection of exchange sensor on Connext The CT must be positioned according to the diagram shown in Figure . Then check the direction of the current measured by the CT. Procedure: Photovoltaic system switched OFF Loads switched ON (e.g.

  • Page 33: Configuration 5 - System With Azzurro Three-Phase Photovoltaic Inverter

    Solo documento principale. 5.5. Configuration 5 – System with Azzurro three-phase photovoltaic inverter Figure 31 - Configuration 5 with three-phase string inverter Follow the instructions to connect the RS485 port to Azzurro three-phase photovoltaic inverters. 1) Use a COM connector to connect to one of those identified as RS485 on the inverter (check the manual of the inverter in question).
  • Page 34 Solo documento principale. RS485 Pin 24-pin terminal block RS485 + (Red)/ 1 RS485 – (Black)/ 3 Table 12 - RS485 connections to photovoltaic inverter The exchange must be measured via a three-phase meter, configured as follows. Figure 33 - RS485 connection on meter side Pin Meter 24-pin terminal block Table 12 - RS485 connections to three-phase meter...

  • Page 35: Systems Without Zcs Azzurro Inverter

    Configuration 6 – System with single-phase photovoltaic production If one or more single-phase photovoltaic inverters do not belong to the ZCS Azzurro brand, two accessory sensors (ZSM-ACC-TA) must be installed. The sensor must be positioned directly at the output of the photovoltaic inverter on the AC side.
  • Page 36 Solo documento principale. Figure 36 - NON-Azzurro production sensor connection on Connext Sensor cable 24-pin terminal block Black cable Red cable Table 14 - Exchange sensor connections Figure 37 - Connection of exchange sensor on Connext The direction of the arrow on the current sensor represents the installation direction.

  • Page 37: Configuration 7 - System With Three-Phase Photovoltaic Production

    Solo documento principale. Check the positioning of the production CT (Figure 36). The value shown on the Connext display must be same as that shown by the inverter. Check the positioning of the exchange CT (Figure 37). Procedure: Photovoltaic system switched OFF Loads connected The power from the grid must be negative (i.e.
  • Page 38 Solo documento principale. Sensor cable 24-pin terminal block Black cable Red cable Table 15 - Photovoltaic sensor connections Figure 39 - Connection of NON-Azzurro production sensor on Connext Figure 40 - RS485 connection on meter side Pin Meter 24-pin terminal block Table 16 - RS485 connections to three-phase meter Connext User Manual Rev.
  • Page 39 Solo documento principale. Figure 41 - RS485 connections with exchange meter Follow the meter’s manual to configure it correctly, setting the communication address to 32. The direction of the arrow on the current sensor represents the installation direction. Pay attention to the insertion direction Note The meter settings can be checked in Appendix B –...

  • Page 40: Configuration 8 - Single-Phase System Without Photovoltaic Production

    Solo documento principale. 6.3. Configuration 8 – Single-phase system without photovoltaic production Figure 42 - Configuration 8 of single-phase system without production If there is no Azzurro string or hybrid inverter, the Connext can still be used to manage the wallbox. It is only necessary to measure the exchange with a sensor.

  • Page 41: Configuration 9 - Three-Phase System Without Photovoltaic Production

    Solo documento principale. Figure 43 - Connection of exchange sensor on Connext 6.4. Configuration 9 – Three-phase system without photovoltaic production Figure 44 - Configuration 9 of three-phase system without photovoltaic production Connext User Manual Rev. 2.2 10/01/2023 41/67 Identification: MD-AL-GI-00 Rev.
  • Page 42 Solo documento principale. If there is no storage system inverter belonging to the Azzurro brand and the photovoltaic production needs to be measured, an accessory meter (ZSM-METER-DTSU) must be installed. The Meter must be placed directly on the output of the exchange meter and connected to the Connext system via the RS485 port following the pin-out shown.

  • Page 43: Initial System Configuration

    Solo documento principale. 7. Initial system configuration The Connext must be powered and connected in order to proceed with the registration of the system. The device is connected when one of the two symbols shown Figure 47 in the display appears. Figure 47 - Connext in GSM (left) or LAN (right) 7.1.
  • Page 44 Solo documento principale. Owner Administrator User Choose Administrator account Change system power Add devices Change charging strategy (EVC) System monitoring Table 19 - Account levels Figure 49 - Access to Azzurro Systems app Any systems already registered on the account used will be imported, and new ones can be added by clicking the + icon located on the bottom right of the screen The "With Connext"...
  • Page 45 Solo documento principale. Figure 50 - Add system with Connext Figure 51 - Configuration of system with Connext (1) If Connext has already been registered by an account, it will no longer be possible to become its owner. The power set must be the power contracted with the electricity supplier and is the maximum power that can be drawn from the meter.
  • Page 46 Solo documento principale. Figure 52 - Configuration of system with Connext (2) The system configuration must be indicated, whether single-phase or three-phase. IMPORTANT: do not indicate whether it is a single-phase or three-phase inverter, but the system. The location of the system allows for correct weather and time data. Figure 53 - Verification of Connext registration Connext User Manual Rev.

  • Page 47: Adding An Azzurro Inverter

    Solo documento principale. 7.2. Adding an Azzurro inverter When the configuration is complete, the list of connected devices and the settings of the system can be checked. Figure 54 – Adding devices To add devices, click the + icon, click “Add inverter” and enter the serial number of the Azzurro inverter.

  • Page 48: Adding Measuring Systems

    Solo documento principale. Figure 55 - Inverter communication address 7.3. Adding measuring systems There are different options: an inverter and sensors cannot be inserted on the same system. If there is no inverter, select "Add sensors." To add measuring devices in Configuration 6 (6.1), Configuration 7 (6.2), Configuration 8 (6.3), Configuration 9 (6.4), select the correct multiplication constant: 1 for single-phase systems, 3 for three-phase systems.

  • Page 49: Adding And Managing Wallboxes

    Solo documento principale. Figure 56 - Adding measuring sensors 7.4. Adding and managing wallboxes NB: the wallbox is recognised automatically. Make sure it is powered and set on Plug&Play. If the wallbox is added later, it can be registered using the serial number. Figure 57 - Adding a wallbox Connext User Manual Rev.
  • Page 50 Solo documento principale. Figure 58 - Wallbox operating status When the connector of the car is plugged in and if the car itself allows it, the charging can be started or stopped remotely. Figure 59 - Remote start/stop Connext User Manual Rev.
  • Page 51 Solo documento principale. Charging strategies Strategies can only be changed by Administrators and the Owner when a charging session is not in progress. Kilometre Strategy (Single) Based on the consumption of the vehicle entered (Wh/km), the vehicle is charged with enough energy in kWh to cover the desired distance in kilometres, in addition to the charge already present in the vehicle.
  • Page 52 Solo documento principale. Figure 60 - Charging strategies Connext User Manual Rev. 2.2 10/01/2023 52/67 Identification: MD-AL-GI-00 Rev. 1.2 07.06.21 - Application: GID...

  • Page 53: Dry Contact Management

    Solo documento principale. 8. Dry contact management The Connext device can also be used to manage external loads such as heat pumps, hot water boilers, etc. There are 4 outputs in total, please refer to the table below for physical connections. Output on app 24-pin terminal block Output 1...
  • Page 54 Solo documento principale. Figure 62 - Setting dry contacts (2) Figure 63 - Setting dry contacts (3) Connext User Manual Rev. 2.2 10/01/2023 54/67 Identification: MD-AL-GI-00 Rev. 1.2 07.06.21 - Application: GID...
  • Page 55 Solo documento principale. The maximum threshold represents the minimum value (W or %) of output activation, if this value is not reached, the contact is open (e.g. 2000W → power generated, contact open, heat pump off; battery with SoC = 65% → contact open, heat pump off). When this value is reached, the contact closes and the logic comes into operation.

  • Page 56: Access For Maintenance Only

    Solo documento principale. 9. Access for maintenance only The Connext system allows internal access via USB for any extraordinary maintenance. To access, the following materials and tools are required: USB Cable (type C) Laptop or notebook Configuration software supplied by AZZURRO Maintenance should only be carried out if explicitly requested by Azzurro technical support.

  • Page 57: Technical Datasheet

    Solo documento principale. 10. Technical datasheet Connext User Manual Rev. 2.2 10/01/2023 57/67 Identification: MD-AL-GI-00 Rev. 1.2 07.06.21 - Application: GID...

  • Page 58: Maintenance

    Solo documento principale. 11. Maintenance 11.1. Troubleshooting Follow the access procedure for maintenance and contact the supplier. Visit the website www.zcsazzurro.com. 11.2. Maintenance Connext systems generally do not require daily or routine maintenance. Connext User Manual Rev. 2.2 10/01/2023 58/67 Identification: MD-AL-GI-00 Rev.

  • Page 59: Dismantling And Disposal

    Solo documento principale. 12. Dismantling and disposal The packaging materials are environmentally friendly and can be recycled. Therefore, they can be disposed of in the appropriate recycling containers in accordance with the local waste disposal regulations. However, the device cannot be disposed of as household waste, but must be treated as special waste.

  • Page 60: Warranty Terms And Conditions

    13. Warranty terms and conditions To view the “Warranty Terms and Conditions” offered by ZCS Azzurro, please refer to the documentation inside the product box and on the website www.zcsazzurro.com.

  • Page 61: Appendix A - Wallbox Settings

    Solo documento principale. 14. Appendix A – Wallbox settings Registration of the wallbox on the Connext System via the app must be carried out with the wallbox switched on and set to Plug&Play operating mode. Wallbox settings can be changed using the front keypad. Back Next Cancel/Back...
  • Page 62 Solo documento principale. Set PWD Set Mode Set Current Figure 68 - Password setting, Mode of Use and Power configuration screen 4) To set the mode of use, select ‘Set Mode’ from the screen shown in the Figure, two screens (Figure 69 -a and Figure 69 -b) will open in sequence within a few seconds of each other.
  • Page 63 Solo documento principale. 1. Add Card 2. Remove Card Figure 70 - RFID card control screen 3) To add charge-enabling cards, select '1. Add Card' and place the RFID card in front of the symbol below. Supports up to 8 cards Existing: x Swipe to add card...

  • Page 64: Appendix B - Meter Settings

    Solo documento principale. 15. Appendix B – Meter settings The power cables for phases R, S, T and the neutral cable (N) are connected to the meter via pints 2, 5, 8 and 10, respectively. The CTs for measuring the current are connected: - R-phase measurement with the terminals connected to PIN 1 (red wire) and PIN 3 (black wire).
  • Page 65 Solo documento principale. 1. Press to: • “Confirm” • “Move cursor” (to enter digit) 2. Press to “go back” 3. Press to “add” Figure 89 - Meter Legend Meter configuration To configure the device in read mode, enter the settings menu as shown below: 1.
  • Page 66 Solo documento principale. Note: In case of error, press “ESC” and then “SET” again to reset the required code. 4. Confirm by pressing SET until you enter the settings menu. 5. Enter the following menus and set the parameters indicated: a.
  • Page 67 Solo documento principale. iii. Press “ESC” to confirm. Connext User Manual Rev. 2.2 10/01/2023 67/67 Identification: MD-AL-GI-00 Rev. 1.2 07.06.21 - Application: GID...

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