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ZCS AZZURRO Corebox ZVD-30K-CORE User Manual

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Summary of Contents for ZCS AZZURRO Corebox ZVD-30K-CORE

  • Page 2 Corebox series DC30K-E2C22-75 User Manual Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 1/79...
  • Page 3 (including the software), reproduced or distributed in any form or by any means without the permission of Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right to final interpretation. This manual is subject to change based on feedback from users, installers or customers.

  • Page 4: Table Of Contents

    Table of Contents Preliminary safety instructions ......................... 7 1.1. Safety instructions ......................... 7 1.2. Symbols and icons ........................13 1.3. Labels ............................14 Product Overview ............................ 15 2.1. Product Introduction ........................15 2.2. Inside view ........................... 16 Installation ............................... 17 3.1.
  • Page 5 7.1. Indicator description ........................55 7.2. LCD information ........................... 55 7.3. Settings ............................57 7.4. Checks before initial startup ......................64 7.5. Checks before switching on for the first time ................65 7.6. Checks when switching on for the first time ................65 Appendix-Working principle diagram .....................
  • Page 6 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 connection, commissioning, maintenance and troubleshooting of the DC-030K-E2C22-75: Keep this manual so that it is accessible at all times.
  • Page 7 Note: provides important tips on the correct and optimal operation of the product Note Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 6/79...

  • Page 8: Preliminary Safety Instructions

    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 Highlights the safety instructions to be followed during installation and use of the equipment. Before installing and using the equipment, make sure you read and understand the instructions in this manual and familiarise yourself with the relative safety symbols shown in this chapter.
  • Page 9 Observe the instructions in this manual and any applicable local laws. If the local laws contradict with the instructions in this manual, the local laws will be applied. In the case of any conflict or contradiction between any requirements or procedure contained in this manual and any such local laws and/or rules, obey the local laws and/or rules, requirements, and processes established in this manual, if and to the degree permitted by law.
  • Page 10 Protect the DC Charger with the safety equipment and procedures specified by local regulations. If it is necessary to remove safety equipment, replace them as soon as possible once the work is completed. Wear the appropriate personal protective equipment (PPE). Do not use the DC Charger and immediately get in contact with the manufacturer if the safety or the safe use of the DC Charger is at risk.
  • Page 11 For the safety of human and the vehicle, it is strictly forbidden to pull out the charging connector during the charging process. If there is any abnormality during use, press emergency button immediately to cut off all input and output power. Danger In case of flooding, do not operate your charger while it or your vehicle is submerged in water.
  • Page 12 Attention Do not remove the information label or tamper with the charging station. Otherwise, ZCS will not provide any warranty or assistance Note Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 11/79...
  • Page 13 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 Do not touch the terminal or the conductor connected to the may cause electrocution or fire! electrical grid.

  • Page 14: Symbols And Icons

    Introduces the main safety symbols on the charging station. 1.2. Symbols and icons Some safety symbols are located on the charging station. Read and understand the contents of the symbols before installation: Be careful of high voltage Complies with the European Standards Ground connection point Read this manual before installing the charging station.

  • Page 15: Labels

    1.3. Labels DO NOT remove the labels. DO NOT cover with sheets, supports, cabinets, etc. Always keep them clean and legible. Figure 2 - Labels present on the charging station Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 14/79...

  • Page 16: Product Overview

    2. Product Overview 2.1. Product Introduction Connector CCS2 Outdoor IP54 Figure 3 – Dimension Start mode APP/RFID Installation Wall or Pillar (optional) LED indicator Touch screen Air inlet Input cable Figure 4 – Detail Charging connector Ethernet inlet Emergency stop button Air outlet Touch screen Hanger...

  • Page 17: Inside View

    2.2. Inside view Tamper detection Circuit breaker Switch mode power supply AC contactor Relay switching board Time relay PLC converter Terminal block Charging control board Main control board DC meter Gateway RFID card sensor area Emergency button Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 16/79...

  • Page 18: Installation

    3. Installation Figure 5 - Installation procedure 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. • Take into account the weight of the charging station during Danger transport and installation.
  • Page 19 Contents of the packaging Part Fast Charger Mounting bracket M8*60 Anchor bolt M12*100 Anchor bolt RFID activation card M6*16 Screw Expansion pipe Self-tapping screw Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 18/79...
  • Page 20 Cable holder PillarPillar Ferrule Power module Wire tiest Internal triangle wrench Declaration of Conformity User Manual Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 19/79...
  • Page 21 Warranty Table 2 – Package contents The M12*100 Anchor bolt and the PillarPillar are optional, so please ensure that you have choosen the pillar, otherwise your delivery will not include these two. Note Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 20/79...

  • Page 22: Installation Tools

    The following tools are required for the installation of the charging station and electrical connections; 3.1.1. Installation tools therefore, they must be prepared before installation. Tool Function To screw and unscrew Cross Screwdriver screws for the various connections To screw and unscrew Flathead screwdriver screws for the various connections...
  • Page 23 RJ45 connector crimping To crimp the cables plier To insert the expansion plugs Rubber hammer into the wall holes To check the voltage and Multi-meter current values To mark the wall for better Marker pen fixing precision Measuring tape To measure distances To make sure the bracket is Level level...

  • Page 24: Movement Of The Charger

    1) Open the packaging and remove the polystyrene protection cover, insert your hands into the slots 3.1.2. Movement of the charger and take hold of the device; 2) Lift the charging station from its packing box and move it to the installation position, then remove the polystyrene protections.

  • Page 25: Recommended Sizes For Installation

    3.2.1. Recommended sizes for installation The charger is recommended to be installed above the ground by 1.2m. The distance between two chargers is at least 1m. The holder for the charging connector is recommended to be installed above the ground by 1m. Manual of 09/02/2024 Rev.

  • Page 26: Installation

    4. Installation Please disconnect the power supply before proceeding with installation work • Danger 4.1. Preparation Step1: Site preparation. Keep charger adjacent space no less than 1 meter at all directions with no object. Step2: Prepare the installation foundation properly with concrete construction. Step3: Ensure the vertical tilt angle no more than 5%.
  • Page 27 You can make four marks overall based on any one hole in the four corners of the mounting bracket, however it is recom- mended to keep it symmetrical. Note Step2: Use the electric drill to drill four holes on the marks made at the previous step. Step3: Use a hammer to hammer the whole anchor bolt into the holes.
  • Page 28 Step4: Install wall-mounted plate. Hang the mounting bracket by in- serting the exposed screw through the hole on the mounting bracket. Step5: Put the nuts onto the screws to secure the mounting bracket firmly. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 27/79...
  • Page 29 Step6: Hang on the charger, and fasten the fixture bolt at both sides. Step7: To hang the charger, insert the edges of two parallel iron rods of the mounting bracket into the hooks on the back of the charger to get stuck, and fasten the char- ger with two screws. Manual of 09/02/2024 Rev.
  • Page 30 Step8: Loosen the 8 screws on the cover of the power module. Step9: Use a flat-head screwdriver to turn the "arrow" knob so that the arrow points to the number 0. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 29/79...
  • Page 31 Step10: Gently place the power module into the cabinet. Step11: Close the cover. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 30/79...
  • Page 32 Step12: Put the 8 screws through the holes in the cover and tighten the screws. Step13: Place the cable holder on to the wall, keeping it vertical and level, and make four markings depending on the cable holder’s holes. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 31/79...
  • Page 33 Step14: Drill four holes with an electric drill on the markings made at previous step. Step15: Hammer the whole anchor bolt into the holes with a hammer. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 32/79...
  • Page 34 Step16: Unscrew the nuts counterclock- wise with an adjustable wrench. Step17: Hang the cable holder by inserting the exposed screws through the holes on the cable holder. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 33/79...
  • Page 35 Step18: Thread the nuts onto the screw to secure the cable holder firmly. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 34/79...

  • Page 36: Pillar-Mounted (Optional)

    The mounting of the fast Charger must be performed on a solid ground, this can be a concrete 4.3. Pillar-mounted (optional) foundation or a concrete floor. When dimensioning the foundation, it is recommended to perform a static load capacity analysis according to relevant norms. As shown below, please follow the instructions below to make the concrete foundation.

  • Page 37: Install The Pillar And The Charger

    4.3.1. Install the pillar and the charger Step1: Align the holes in the pillar with the nuts in the concrete foundation, then tighten the screws. Step2: Place the charger on the pedes- tal's bracket, as shown, and match the ten holes in the pedes- tal with the ten holes on the bottom of the charger.
  • Page 38 Step3: Put the screws through the holes and tighten them to secure the charger onto the pillar firmly. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 37/79...

  • Page 39: Install The Cable Holder

    Step1: Loosen the four screws on the right side of the pillar, and align the holes of the socket hol- ster 4.3.2. Install the cable holder with the installation holes for socket holster on the pillar. Step2: Tighten the screw clockwise to secure the socket holster firmly. Manual of 09/02/2024 Rev.

  • Page 40: The Path Of The Cable

    Step1: The cable will be buried in the ground, then pass through the hole on the left side of the 4.3.3. The path of the cable concrete foundation and exit through the hole on the top side of the foundation to pass through the pillar and exit through the hole on the left side of the pillar.
  • Page 41 Step2: Use the electric drill to drill four holes on the marks made at the previous step. Step3: Hammer the whole anchor bolt into the holes with a hammer. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 40/79...
  • Page 42 Step4: Loosen the nuts counterclockwise with an adjustable wrench. Step5: Put the four protruding screws through the pillar's four holes. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 41/79...
  • Page 43 Step6: Put the nut onto the screw to secure the pillar firmly. Step7: The pillar installation completed. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 42/79...
  • Page 44 Step8: Align the ten holes of the pillar with the ten holes on the bottom of the Charger. Step9: Tighten the ten screws to secure the Charger onto the pillar firmly. For holder installation, please refer to the section "Install the •...

  • Page 45: Module Installation

    4.4. Module installation Step1: Take off the side panel (keep screws properly) Step2: Insert the module and fasten screws 4pcs M4 x 12mm. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 44/79...
  • Page 46 Step3: Put back the side panel. Caution: LED indicator shall be kept on the upside. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 45/79...

  • Page 47: Wiring

    4.5. Wiring 4.5.1. Connect power cable Step1: Stripe 90 mm of the cable sheath. Stripe 10 mm of the wire sheath. Strain the exposed copper Figure 7 – Hardwire wires and insert them into the ferrules. Crimp the terminals with the crimping piler. Note: the recommended wire diameter is 16mm Manual of 09/02/2024 Rev.
  • Page 48 Step2: Use the wrench to loosen the cable gland on the bottom of the cabinet, and put the cable through the cable gland. Please keep in mind that the circuit breaker is OPTIONAL; the • diagrams below show these two wiring options. Loosen the screws on the terminal block as directed, then insert •...
  • Page 49 Step4: Without circuit breaker Step5: Connect PE wire. Loosen the screws with a flathead screwdriver. Insert the ferrule-crimped PE wire into the port, and tighten the screws. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 48/79...

  • Page 50: Ethernet Cable & Rs485 Cable & Sim Card

    4.5.2. Ethernet cable & RS485 cable & SIM card Step1: Strip the cable and wire sheath with the wire stripper. Step2: Insert the wires into the RJ45 connector, and crimp the wires with the crimping plier. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 49/79...
  • Page 51 Step3: Connect the RS485 cable and Ethernet cable as shown, put their connections into the ports indicated by the arrows, and secure the cables with a tie where there is a tie hole. Step4: If you choose the 4G version, find the PCB located in the same location as the Ethernet PCB, then gently slide the cover and flip it open, then insert the SIM card.

  • Page 52: External Protection Devices

    The charging station is equipped with a Residual Current Device (RCD) to detect any current faults. It 4.6. External protection devices is also equipped with a detection system for DC components above 6mA. It is recommended to install a magnetothermal device with a suitable capacity on the AC connection cables for installation, uninstallation, maintenance and disconnections caused by other reasons.

  • Page 53: Commissioning

    6. Commissioning 6.1. Configure the network for the charger If you select Wi-Fi or 4G for communication, you need to use AP mode to configure the network for the charger. AP mode, which is similar to a local area network, operates the internet locally between your phone and the charger.
  • Page 54 Step2: Configure Wi-Fi or 4G . After logging in, and you will be prompted with the following interfaces: obtain from the operator of 4G card The address of Evchargo Cloud platform: wss://ocpp16.evchargo.com:33033 Attention Click and you will see interface as shown on the right side above, then enter the information to configure the network.

  • Page 55: Connect Charger To Evchargo Portal

    Once the network setting is complete and the charger is online, it is able to connect to 6.2. Connect charger to Evchargo portal Evchargo platform, where you can configure your charger and charge station. When you purchase our charger, after your request, you will be given an account. With this account, you will be able to log in to our platform (Evchargo cloud) and configure the charger’s details.

  • Page 56: Operations

    7. Operations After the charger is installed, please follow the steps below to test whether the charger can charge the car 7.1. Indicator description Yellow indicator keeps on The charging connector has been plugged in Indicator Description Green indicator keeps on Idle Red indicator keeps on Faults...
  • Page 57 If App is chosen, then the user manual of App as shown. Note The user needs Note Select the start mode within the remaining operation time or the operation timeout, and the user needs remove the connector before plugging it back in. During charging session, and the charging details displayed.

  • Page 58: Settings

    The payment details as shown. 7.3. Settings You can do tasks in these pages, as shown. To view the tariff of this fast charger, tap on the standby page. To view the basic information of the fast charger, tap on the standby page. Manual of 09/02/2024 Rev.
  • Page 59 To enter the setting page, you need to tap on the standby page then enter the password: 123456. Only for technician! ZCS won’t provide any support in case of damage related to bad configuration. Note To view the charge record, tap >...
  • Page 60 To view the Fault history, tap > To view the Real-time fault, tap > To view the operating information of the system, tap To view the operating information of BMS (battery management system),tap Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 59/79...
  • Page 61 To view the operating information of Charger, tap To view the operating information of module, tap To set the basic information of this fast charger, tap Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 60/79...
  • Page 62 To set the password, tap To set the protection, tap To set the tariff, tap Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 61/79...
  • Page 63 To set module, tap To set BMS (battery management system), tap To set module, tap Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 62/79...
  • Page 64 To reset the QR code address and the charger type tap To view the version information of the fast charger, including software, serial number, etc. Tap To view the log of the version, tap Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 63/79...

  • Page 65: Checks Before Initial Startup

    The operation of this DC charger must be performed in accordance with the test instructions outlined 7.4. Checks before initial startup below. All of the instructions given below are required and must be followed by the operator of the DC charger.

  • Page 66: Checks Before Switching On For The First Time

    been mounted, in accordance with the site- Residual current protection device （if have） specific conditions and the valid standards. Check the charging cable, charging connector Check the charging cable, charging connector, and outside surface of the cabinet for damage and the outside surface of the cabinet. and scratches, etc.

  • Page 67: Appendix-Working Principle Diagram

    8. Appendix-Working principle diagram Circuit breaker Main control panel Lightning arrester DC control panel Auxiliary switching power supply Power module Charge cable DC contactor Display screen Fuse Card reader K1/K2 Shunt Emergency stop DC watt-hour meter Entrance control LED light board AC power line COLOR DESCRIPTION...

  • Page 68: Led Indicator

    9. LED Indicator There are 2 LED indicators next to charger interface. State Power-on, Description LED Status Standby Green light normally on connector plug-in Connector plug-in, and charging Yellow light flashing at the Ready to charge interval of 1S started yet Green light flashing at the In charging Charging started...

  • Page 69: Technical Datasheet

    10. Technical datasheet Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 68/79...

  • Page 70: Troubleshooting And Maintenance

    Solo documento principale. 11. Troubleshooting and maintenance This section contains information and procedures on how to troubleshoot any faults and errors 11.1. Troubleshooting that may occur during operation of the charging station. If you have any problems please follow these steps: 1) Check the warning messages and error codes on the information panel of the device.
  • Page 71 Solo documento principale. 2. If the frequency exceeds 63Hz for a short time, wait till power grid recover to normal voltage range. 1. Check the input voltage frequency from the backend. E005 Input lower frequency 2. If the frequency is lower than 47Hz for short time, wait till power grid recover to normal voltage range.
  • Page 72 Solo documento principale. Output over-voltage 1. Check whether the output voltage is The set demand voltage within parame- ters setting range. If not, E024 exceeds the maximum please check whether output output voltage of the voltage/current is too high, or the charger parameters setting is reasonable.
  • Page 73 Solo documento principale. DC connector (on the E039 display board) failure The battery voltage is E040 incorrect E041 The module address error Module output is short- E043 circuit The module is not E044 enabled,unavailable The main control board is E048 overtemperature The output voltage exceeds the maximum allowable...
  • Page 74 Solo documento principale. E054 Door access control failure Card reader E055 communication error Screen communication E056 error Communication failure between main control E057 board and the control board The insulation resistance is E059 too small and charging is not allowed Excessive deviation of demand voltage from E061...
  • Page 75 Solo documento principale. Charging cable connection 1. Check if charging cable connection is E062 abnormal correct and firm. The output wires are E063 connected reversely Note: If the above problems cannot be resolved, contact your dealer. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 74/79...

  • Page 76: Maintenance

    Solo documento principale. 11.2. Maintenance Please note that he maintenance should be done by the qualified person. For maintenance of non-electrical parts, please disconnect the power supply first Attention For the safe operation of the fast charger, regular maintenance or control of the safety equipment is required.
  • Page 77 Solo documento principale. Check if the interior of the control cabinet is clean and without any traces of condensation. Check for cleanliness and Check the water run-off on Daily condensation cable plug holder and charging connector. Check the seal for damage and correct positioning.
  • Page 78 Solo documento principale. Press the emergency stop Function test of the button, and the code "E008" Once a month emergency stop displayed on the screen. Manual of 09/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 30K CORE” 77/79...

  • Page 79: Dismantling And Disposal

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

  • Page 80: Warranty

    Solo documento principale. 13. Warranty Zucchetti Centro Sistemi SpA provides a warranty of 2 years from the date of installation of the charging station, subject to registration on the website https://www.zcsazzurro.com/it/estensione-garanzia. During the warranty period, Zucchetti Centro Sistemi S.p.A. guarantees the normal operation of the charging station. If the device is defective or faulty during the warranty period, contact your installer or supplier.

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Corebox dc30k-e2c22-75

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