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ZCS Azzurro EV CHARGER 1PH 7kW User Manual

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Summary of Contents for ZCS Azzurro EV CHARGER 1PH 7kW

  • Page 1 EV CHARGER 1PH 7KW...
  • Page 2 Solo documento principale. EV CHARGER 1PH 7kW User Manual Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 1/62...
  • 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

    Solo documento principale. Table of Contents Preliminary safety instructions ......................8 1.1. Safety instructions .......................... 8 1.2. Symbols and icons ........................12 1.3. Labels ............................13 Product features ..........................13 2.1. Product presentation ........................14 2.2. Operating diagram ........................15 Installation ............................
  • Page 5 Solo documento principale. 7.1. Procedure ............................. 33 7.2. Password setting, mode of use and power limitation ..............34 7.3. Menu for repairs or maintenance ....................36 7.4. Configuration of RFID card (to enable charging in online and offline mode) ......37 Working mode .............................
  • Page 6 Solo documento principale. Troubleshooting and maintenance ....................57 12.1. Troubleshooting ........................... 57 12.2. Maintenance ..........................60 Dismantling and disposal ........................ 61 Warranty ............................62 Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 5/62...
  • Page 7 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 connection, commissioning, maintenance and troubleshooting of the EV CHARGER: 1PH 7kW Keep this manual so that it is accessible at all times.
  • Page 8 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 the correct and optimal...

  • Page 9: 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 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 10 Solo documento principale. Do not place the charging station near explosive, flammable materials, chemical vapours or potentially hazardous materials. Danger Figure 1 – Do not lose or damage this manual Transport requirements If you encounter problems with the packaging that could damage the charging station or if you find any visible damage, immediately notify the transport company.
  • Page 11 Attention Do not remove the information label or tamper with the charging station. Otherwise, ZCS will not provide any warranty or assistance Note Operation Do not use the product if it has any defects, cracks, scratches or leaks, but contact your dealer or ZCS technical service.
  • Page 12 Solo documento principale. Disconnect the input and output power supply If the charging station is not functioning properly: • Warning Take special care when charging in thunderstorms or in rain Attention Maintenance and repair Keep the charging station clean and dry; if you need to clean it, use a clean dry cloth. It is very dangerous to touch the inside of the charging station, therefore it is strictly forbidden to do so while the system is running.

  • Page 13: Symbols And Icons

    Solo documento principale. 1.2. Symbols and icons Introduces the main safety symbols on the charging station. 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 14: Labels

    Solo documento principale. 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 2. Product features Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 13/62...

  • Page 15: Product Presentation

    Solo documento principale. 2.1. Product presentation The EV CHARGER 1PH 7kW series are electric vehicle battery chargers that can communicate with the Battery Management System (BMS) of vehicles and provide them with the power needed for charging, thus guaranteeing the protection of the electrical system. They do not convert the mains voltage or current but simply regulate the flow and have internal protection devices in case of short circuit or other types of battery faults.

  • Page 16: Operating Diagram

    Solo documento principale. Figure 4 – Front and side view of the charging station 2.2. Operating diagram Figure 5 – Operating diagram of the charging station The charging station connects to an electric vehicle via a Type2 connector (the cable is optional). According to the standards, the charging station is identified with Type3 (wall-box) in which the station is responsible for any power limitations, protections of various types and start-stop charging.
  • Page 17 Solo documento principale. The station is equipped with a MID metering system that measures the energy supplied to the Figure 6 - Type2 connector vehicle. The possible connection with an external communication gate also allows remote control of the station, billing of the energy and other functions. It is compatible with all types of cables and power sockets in order to ensure safe charging.

  • Page 18: Installation

    Solo documento principale. 3. Installation Figure 7 - 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 Solo documento principale. Contents of the packaging Part Charging station Screw with built-in washer Front opening keys RFID activation card Expansion plug Self-tapping screw Quality inspection sheet Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 18/62...

  • Page 20: Installation Tools

    Solo documento principale. Jig for wall holes Warranty Table 2 – Package contents 3.1.1. Installation tools The following tools are required for the installation of the charging station and electrical connections; therefore, they must be prepared before installation. Tool Function To screw and unscrew Screwdriver screws for the various...
  • Page 21 Solo documento principale. 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 ESD gloves...

  • Page 22: Installation Process

    The installation location chosen should allow easy access to the charging station for normal operation and maintenance. For safety reasons, ZCS and/or its authorised partners may not perform repairs/maintenance or move the chargers from and to the ground if they are installed at a height of more than 180 cm.
  • Page 23 Solo documento principale. 0.15 mm × 18mm; 0-600V; Insulating tape Second requirement 0°C-80°C Cable tie 4 × 200mm Second requirement It is important that all cables used are suitable for outdoor use Table 4 - Electrical equipment NOTE: For safety reasons, make sure to use suitably sized cables, otherwise the current may cause overheating or overloading, which could result in a fire.

  • Page 24: Electrical Connections

    Solo documento principale. 4. Electrical connections This chapter describes the electrical connections of the 7kW charging station. 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 25 Solo documento principale. Figure 9 – Preparing the ground cable (1) 1) Insert the exposed wires into the OT terminal and crimp them using a crimping tool, as shown in relative Figure. Note 1: L3 is the length between the insulation layer of the ground cable and the crimped part. L4 is the distance between the crimped part and the conductor wires protruding from the crimped part.

  • Page 26: Connecting The Ac Power Cables

    Solo documento principale. Figure 11 - Connecting the ground terminal 4.2. Connecting the AC power cables Connect the station to the AC power supply network or power grid using AC power cables. The AC power cables used for the charging station must be three-pole outdoor cables. For easier Context installation, use flexible cables.
  • Page 27 Solo documento principale. 2) Connect the AC power cable according to the following criteria: Figure 12 - Connecting the AC output cables (1) Connect the ground wire (yellow-green) to the hole labelled “PE”, and tighten the cable using a screwdriver as described in the previous paragraph. •...

  • Page 28: External Protection Devices

    Details on EN-GATE or ZCS Connext can be found in the specific manual. For more information and instructions on how to connect the cables, contact ZCS technical service. The connection is possible using the CAN ports shown in the figure. There are two connectors as it is possible to connect up to 12 charging stations to the same external device.
  • Page 29 Solo documento principale. When grouping chargers together, for example, in public car parks, a single gate functions as an access gate for up to 12 chargers. The gate is connected to charger #1 and the other chargers are connected one by one via network cables between the various CAN ports (relative Figure). The length of the network cable between the gate and charger #1 should be ≤10m, while the total length of the network cables between the gate and the farthest charger should be ≤100m.

  • Page 30: Mounting

    Solo documento principale. 5. Mounting 1) Identify the installation position and mark the two holes for the wall screws, which will be 5.1. Wall mounting inserted in the top rear of the charging station. You can use the hole jig found in the package. 2) Drill two holes with the 6mm diameter drill bit and insert the plugs horizontally into the holes, paying attention to the force and depth with which they are inserted (make sure the plug completely enters the hole).

  • Page 31: Mounting On Metal Support

    Solo documento principale. Figure 17 – Wall fixing 1) After positioning the metal support and routing the connection cables, place the station on top 5.2. Mounting on metal support of the support. 2) Fix the station from below using the screws contained in the mounting kit. Figure 18 - Positioning of support post Manual of 13/08/2024 Rev.

  • Page 32: Locking

    Solo documento principale. 5.3. Locking The locking of the charger housing does not depend on the type of mounting. Turn on the switch inside and close the front cover of the charger with the wrench supplied. The locks are located on the right side. LOCK Figure 19 - Side view of charger Pressing lightly on the front cover will make it easier to close and...

  • Page 33: Commissioning

    Solo documento principale. 6. Commissioning 6.1. Preliminary safety inspection Make sure that the AC voltage falls within the range permitted by the device. Attention Check the following points before starting up the charging station: 1) Positioning: Check that the position is stable and solid and that the charging station does not move unintentionally.

  • Page 34: Configuration

    Solo documento principale. 7. Configuration Configuration is necessary for the commissioning of the electric vehicle charging station; without it the charger may not work or may work incorrectly Note 1) After installing the charging station properly (see sections 2, 3, 4, and 5), power it up and check 7.1.

  • Page 35: Password Setting, Mode Of Use And Power Limitation

    Solo documento principale. 1. Setting 2.Maintenance 3. Management Figure 23 - Main configuration screen 1) From the screen shown in relative Figure, select point ‘1. Settings’ and press the Confirm/Enter 7.2. Password setting, mode of use and power limitation key. Wait for the page shown in relative Figure to appear. Set PWD Set Mode Set Current...
  • Page 36 Solo documento principale. Once the password has been changed, you will no longer be able to reset it. Losing the new password means losing access to the device for future configuration changes. Therefore, it is highly recommended not to change the password.

  • Page 37: Menu For Repairs Or Maintenance

    Solo documento principale. 10 A 16 A Current: 32A 6) Select the desired current limit. The following power limits can be set: Figure 27 - Screen for setting the current limit 32A corresponds to the maximum limit of 7kW for single-phase and 22kW for three-phase; 25A corresponds to the maximum limit of 5.8kW for single-phase and 17.3kW for three- phase;...

  • Page 38: Configuration Of Rfid Card (To Enable Charging In Online And Offline Mode)

    Solo documento principale. 2 <yes> Select yes, restart in 5s 1 2 3 4 5 6 7 8 9 0 3) Select 'Clear log' from the screen shown in relative Figure to clear the list of events on the Figure 29 - Restart screen device.
  • Page 39 Solo documento principale. 2) To add a card for activating the charging, select ‘1. Add Card’ and wait for the screen shown in relative Figure to appear. Supports up to 8 Existing: x Swipe to add card Swipe the card to be added on the device reader; the reader is recognisable by the symbol shown in Figure 32 - Add Card screen relative Figure present on the front of the device.

  • Page 40: Working Mode

    Solo documento principale. 8. Working mode Refer to chapter 6 for configuring the various modes. This operating mode is typical for large users with multiple battery chargers on the same network 8.1. Online who need to manage charging authorisations, charging bookings, remote stops and starts, billing system, etc.

  • Page 41: Offline

    RFID cards which can be configured to activate the charging. No billing system is implemented in this configuration. The ZCS Connext connection can be used, which only allows the charger to be monitored via the Azzurro portal.

  • Page 42: Plug&Play

    Typical use is for private homes, i.e. end users with an electric car in their garage, possibly with their own photovoltaic system. Applications of this kind concern the use of Connext on the ZCS app which allows you to optimize the amount of energy to be stored, used, etc.

  • Page 43: Zsm-Gateway

    Solo documento principale. 9. ZSM-GATEWAY 9.1. Introduction EN-GATE is a control module for the online management of wallboxes. This user manual is a guide for the installation, commissioning and operation of the ZSM-GATEWAY system, and provides useful information on its technical installation and use. Before any operation, please read this document carefully to understand how the device works.

  • Page 44: Features

    As the OCPP 1.6 position is open, the ZSM-GATEWAY can also easily be coupled with other backends that support OCPP1.6 communication protocols. For more information please contact ZCS Azzurro support. 9.3.2. Management of charger unit In charger units in a car park (for example), a single ZSM-GATEWAY can act as a communication gateway for a maximum of 12 chargers.
  • Page 45 Solo documento principale. Figure 39 - Definition of inputs Figure 40 – Device dimensions Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 44/62...

  • Page 46: Led Indications

    Solo documento principale. 9.3.3. LED indications Reference LED Definition Green light flashing: ZSM-GATEWAY in operation Operating status (left) Green light steady/off: ZSM-GATEWAY not in operation Green light steady: ZSM-GATEWAY and Back-end connected Back-end connection (centre) Flashes once: back-end is communicating Off: connection between ZSM-GATEWAY and back-end failed Green light steady: Connection established Connection to charger (right)

  • Page 47: Zsm-Gateway Positioning

    Solo documento principale. 9.4.3. ZSM-GATEWAY positioning In accordance with the project, route the power and communication cables to the location of the ZSM- GATEWAY. Follow the instructions in this manual regarding the connection of multiple chargers to the same ZSM- GATEWAY.

  • Page 48: Ethernet Connection

    Solo documento principale. 3. The status of the LEDs on the ZSM-GATEWAY should be as follows (left to right): flashing green light, steady green light, steady green light. If the LEDs do not correspond, check the connections and if necessary contact the dealer. 9.6.
  • Page 49 Solo documento principale. 4. When connection with the network has been established, open Google Chrome and type 192.168.5.1 in the address bar; the communication web interface will open for configuring the device. 5. Log in to the page using the credentials: Username: admin Password: admin Manual of 13/08/2024 Rev.
  • Page 50 Solo documento principale. 6. Click on “Search Wi-Fi”, select the available Wi-Fi network and enter the network password. Click “Confirm.” To connect to the device, you need to have a stable signal and know the password of the Wi-Fi network. Manual of 13/08/2024 Rev.
  • Page 51 Solo documento principale. 7. If the connection is successful, the gateway will restart automatically. 8. Wait until the 3 LEDs on the device are all lit up (steady or flashing LEDs), which means that the configuration is successful and the device is ready to communicate. Manual of 13/08/2024 Rev.

  • Page 52: Back-End Configuration

    Solo documento principale. 9.8. Back-end configuration The ZSM-GATEWAY communicates by default with the manufacturer's back-end. If communication with another back-end is necessary, the settings need to be changed. For further information, contact the dealer. 1. From the same initial status page, click “Set ENGATE.” Manual of 13/08/2024 Rev.
  • Page 53 Solo documento principale. 2. When the screen opens, the manufacturer's credentials are present by default. They must be deleted: Server IP: eu.en-plus.con Server Port: 33033 3. Enter the credentials of Azzurro ZCS as follows: Server IP: ocpp16.evchargo.com Server Port: 33033 Click “Confirm.”...
  • Page 54 Solo documento principale. 5. Check that the Wi-Fi and Back-end settings have been saved in the “ENGATE INFO” screen. ocpp16.evchargo.com ocpp16.evchargo.com Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 53/62...

  • Page 55: Evchargo Monitoring Portal

    Solo documento principale. To configure a back-end other than Azzurro, such as public charging networks like EvWay, NextCharge, etc, complete the fields: Server IP Server Port Server Path according to the instructions, and wait for the device to restart. 9.9. EVChargo monitoring portal For the use of the monitoring portal, please refer to the dedicated documentation on the website http://www.zcsazzurro.com/.

  • Page 56: Operation

    Solo documento principale. 10. Operation 10.1. Connecting the charger to the electric vehicle Position the electric vehicle near the charger, making sure the cable is not taut. 1) Pull out the battery-charger cable from the electric vehicle and connect the charger and electric vehicle connectors.

  • Page 57: Technical Datasheet

    Solo documento principale. 11. Technical datasheet Manual of 13/08/2024 Rev. 1.4 “User Manual EV CHARGER 1PH 7kW” 56/62...

  • Page 58: Troubleshooting And Maintenance

    Solo documento principale. 12. Troubleshooting and maintenance This section contains information and procedures on how to troubleshoot any faults and errors 12.1. 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 59 Solo documento principale. 4. if the measurement is normal, but the charger still report the error, there is something wrong with the PCBA of the charger. 1. If the issue is gone when charging a In most cases, the issue is different EV, it means the charger has no related to the EV.
  • Page 60 Solo documento principale. upgrade its firmware to the latest one 1. . check if the meter is on after the charger is powered on. If the meter is not on, Metererror means there is replace the meter. something wrong with the 2.

  • Page 61: Maintenance

    Solo documento principale. NG card means the RFID card NG Card is the invalid one. Check if the card is registered or not. It means the card is used to Card In Use start charging already and the charger has not finished yet. Check if the L and N cable are Meter PhaseError connected correctly.

  • Page 62: Dismantling And Disposal

    Solo documento principale. 13. 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 63: Warranty

    Solo documento principale. 14. 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.

This manual is also suitable for:

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