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ZCS EV CHARGER CARO 3PH 11kW User Manual

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EV CHARGER CARO
1PH 7kW/3PH 11kW
User Manual
Manual of 08/01/2024 Rev. 1.0 "User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW"
1/69

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Summary of Contents for ZCS EV CHARGER CARO 3PH 11kW

  • Page 1 EV CHARGER CARO 1PH 7kW/3PH 11kW User Manual Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 1/69...

  • Page 2: General Instructions

    (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 3: Table Of Contents

    Table of Contents Safety instructions ..........................8 1.1. Safety and Warnings ........................8 1.2. Safety instructions .......................... 9 1.3. Symbols and icons ........................13 1.4. Labels ............................14 Product Overview ..........................15 2.1. Product Features .......................... 15 Exterior Overview ..........................18 3.1.
  • Page 4 6.2. Configuration by AP mode ......................34 6.2.1. Preparation ........................... 34 6.2.2. Login ............................. 34 6.2.3. Configuration ..........................35 6.3. Evchargo APP configuration ......................36 6.3.1. Sign Up and Log In ........................36 6.3.2. Bind Charger to App ........................37 6.3.3.
  • Page 5 9.2. Troubleshooting Technical Faults ....................66 9.3. Maintenance ..........................67 9.4. Storage and Transportation......................68 9.5. Disassembly ..........................68 9.6. Disposal/Scrapping ........................68 Warranty ............................69 Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 5/69...

  • Page 6: Symbols Used

    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 CARO series: 1PH 7kW 3PH 11kW...
  • Page 7 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 operation...

  • Page 8: Safety Instructions

    1. 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 and Warnings Save these instructions. Read all instructions before installing or using the charger. Keep the charger away from explosive or flammable materials, chemicals, vapours and other hazardous objects Keep the charge point socket clean and dry.

  • Page 9: Safety Instructions

    Please consider charge point protection against lightning and heavy rain Keep children away from the charge point During charging, do not drive the EV. Charge only when the EV is stationary. For hybrid cars, charge only when the engine is switched Our packaging materials are environmentally friendly and can be recycled.

  • Page 10: Qualified Personnel

    According to national and local requirements, permission must be obtained from your local provider before connecting to the electrical grid, making sure that the connections are carried out by a qualified electrician. All installation work must be carried out by a qualified and competent electrician.

  • Page 11: Transport Requirements

    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. If necessary, request assistance from an installer or from Zucchetti Centro Sistemi S.p.A.

  • Page 12: Operation

    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. Contact with the electrical grid or the terminal of the equipment...

  • Page 13: Symbols And Icons

    The charging station should start working again after any faults have • been fixed. For repairs, contact your local authorised service centre Do not disassemble the internal components of the charging station • without permission; this will void the warranty. Attention 1.3.

  • Page 14: Labels

    1.4. Labels Figure 2 - Labels present on the charging station DO NOT remove the labels. DO NOT cover with sheets, supports, cabinets, etc. Always keep them clean and legible. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 14/69...

  • Page 15: Product Overview

    2. Product Overview The Caro Product specified in this document is design for the market to charge European Standard plug-in electric vehicles (PEVs), plug-in hybrid electric vehicles (PHEVs), and battery electric vehicles (BEVs). It provides EU standard Type 2 AC charger cable connector. 2.1.
  • Page 16 o Remotely start charging via App o Scheduled charge via App o Eco Mode* o EMS compatible* ✓ Built-in LED charging status indicator. ✓ Network connectivity: WiFi, Ethernet or 4G. ✓ OCPP 1.6 compliant. ✓ CE and CB certified. ✓ Dynamic Load Balancing: The Caro Serials charger has a Dynamic Load Balancing capability which is designed to prevent overloads of the property’s power supply when a electric vehicles is being charged.
  • Page 17 PV energy refers to the electricity produced by solar panels that • transform sunlight into a usable power source for homes and businesses. Attention ✓ Energy management system (EMS) integration The Caro Series chargers are designed with dedicated ports to ensure seamless integration with various EMS systems, providing flexible energy management solutions.

  • Page 18: Exterior Overview

    3. Exterior Overview 3.1. Cable Model 3.2. Model variant Model No. Rating Connector ZV1-7K-CARO-CAB Type 2 Cable ZV3-11K-CARO-CAB 11kW Type 2 Cable Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 18/69...

  • Page 19: Technical Specification

    4. Technical Specification Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 19/69...

  • Page 20: Installation

    5. 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 Before the installation, ensure that: ✓ The charger power is within the allowed load range of the place. ✓...

  • Page 21: Contents Of The Packaging

    If any damage is found or components are missing, contact the supplier and transport company. Contents of the packaging Part Charging station + cable (*3) for single-phase Insulated Terminal (*5) for three-phase M4*32 Screw Wall Plugs RFID activation card Dismounting Tool Manual of 08/01/2024 Rev.
  • Page 22 Cable Holder M4 Hex Key Seal Cup Cable clip M3*12 screw 6 Pins terminal block User Manual Warranty Table 2 – Package contents Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 22/69...

  • Page 23: Required Cable And Accessory

    5.1.1. Required Cable and Accessory Before installation, you will need to prepare the following accessories and cables on your own: To facilitate cabling, aluminium wires and solid copper wires are • not recommended. Ethernet cable, RJ45 connector, and RS485 cable are necessary •...

  • Page 24: Installation Tools

    5.1.2. 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 connections To drill holes in the wall for Electric Drill fixing Electric screw driver...
  • Page 25 To check the voltage and Multi-meter current values To mark the wall for better Marker pen fixing precision Measure the installation Measuring tape height To make sure the bracket is Level (＞ 180mm) level ESD gloves Protective clothing Safety goggles Protective clothing Table 3 –...

  • Page 26: Installation Details

    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 27: Opening

    5.3. Opening Step1: Remove the two screws at the bottom Step2: Use the dismounting tool to pry the marked points (1~3) along the edge in order Step3: Pry the marked points (1~3) along the edge in order Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 27/69...

  • Page 28: Install Wall Mounting Screw

    Step4: Finish opening the external cover 5.4. Install wall mounting screw: Place the positioning diagram on the wall, aligning it properly. Make marks on the wall corresponding to the holes indicated on the diagram. Drill three holes, each 40mm deep, at the marked spots. Drive three wall plugs into the drilled holes, ensuring they are flush with the wall surface.

  • Page 29: Hang The Enclosure On The Screws

    5.5. Hang the enclosure on the screws Position the enclosure on the wall mounting screws by aligning and inserting the protruding screws into the mounting holes on the back of the enclosure. Seal the middle mounting hole with the seal cap. 5.6.

  • Page 30: Connect Ethernet Cable

    5.7. Connect Ethernet cable Use a wire stripper to remove the outer insulation, exposing the inner wires. Arrange the wires in the correct order (T568A /T568B) and insert them into the RJ45 connector. Use a crimping tool to secure the RJ45 connector into the network port as shown below. Manual of 08/01/2024 Rev.

  • Page 31: Connect Rs485 Cable & Ct

    5.8. Connect RS485 cable & CT The locations of the RS-485 and CT ports remain consistent regardless of whether the charger is single-phase or three-phase; their variations in positioning are primarily dictated by the distinct communication methods employed. The charger body is marked with labels for the RS485 and CT ports; •...

  • Page 32: Operation And Configuration

    6. Operation and Configuration 6.1. Charging Operation - Plug & Charge Standby A green indicator flashing slowly for 1s at 3-sec intervals indicates the charger is ready to use. Plug in Plug the charging connector into your EV's charging socket. A green indicator flashing for 200ms at 1-sec intervals indicates the charging connector is plugged in.
  • Page 33 Solid green light indicates the EV is fully charged. Unplug Unplug the charging connector. Return to standby mode after the charging has finished Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 33/69...

  • Page 34: Configuration By Ap Mode

    6.2. Configuration by AP mode 6.2.1. Preparation Activate the Hotspot: Activate the hotspot of the charger by restarting the power. The hotspot of the charger remains available for 15mins since charger reboot. Connect to Charger Hotspot: Turn on the smartphone Wi-Fi, and connect the hotspot of the charger. If unable to connect, try using Airplane mode.

  • Page 35: Configuration

    6.2.3. Configuration Newwork Configuration Click "Network setting", you'll see the following: 1. Communication types The default type will be Wi-Fi. Other options include Ethernet. 2. Wi-Fi name Select the Wi-Fi or enter the Wi-Fi name and enter the password. 3. Server address The default address will be shown here.

  • Page 36: Evchargo App Configuration

    6.3. Evchargo APP configuration Evchargo is an APP that allows electric vehicle drivers to locate public charging stations and intelligently manage their home charging point. It has a simple, easy-to-use design and is dedicated to offering users the best charging and service experience possible. Evchargo Download (IOS&Android) If you are an installer, you can download and install Evchargo App,...

  • Page 37: Bind Charger To App

    6.3.2. Bind Charger to App ✓ Turn on Bluetooth, Wi-Fi and GPS in your mobile phone. ✓ Add the charger through the provided methods. ✓ Select the brand of your charger. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 37/69...

  • Page 38: Select Communication Mode

    6.3.3. Select Communication Mode ✓ The communication modes determines the charging modes you use to charge EV. ✓ If Bluetooth mode and plug to charge mode are selected, it will jump to the charging control page directly. ✓ If online mode is selected, you need to configure network (Wi-Fi or Ethernet) for the charger.

  • Page 39: Transfer Ownership To End User

    6.3.5. Transfer Ownership to End User If you are an installer, after completing the above step and no other functions such as load balancing, PV charging are required, you can use the "Transfer Ownership" feature within the APP to transfer account control to the user.

  • Page 40: Charging Operation

    6.3.6. Charging Operation Plug to charge 1. Turn on the "plug to charge" toggle. 2. Plug the charging connector in, and the indicator 3. flashes green quickly for five times. 4. The indicator gradually brightens, then gradually dims in green while charging in progress. 5.
  • Page 41 Control charging via App Controlling charging process via App is convenient, with two options available: Ethernet, or Wi-Fi, or via Bluetooth. For the Bluetooth, it's important to maintain your phone within the • Bluetooth communication range of charger to ensure a reliable and stable connection.
  • Page 42 Scheduled charging Scheduled charging for EVs lets you set specific times to charge your electric vehicle, helping you save on electricity costs and reduce strain on the grid. ✓ Plug the charging connector in, and the indicator flashes green quickly for five times. ✓...
  • Page 43 Charging by swiping card ✓ Plug the charging connector in, and the indicator flashes green quickly for five times. ✓ Swipe card, and the indicator flashes yellow quickly for up to five times. ✓ During charging, the indicator gradually brightens, then gradually dims in green. ✓...

  • Page 44: Set The Rfid Card

    6.3.7. Set the RFID Card The RFID cards provided with the charger can only be used when the charger is offline. However, if the end user wish to use the card when the charger is online, you will need to link the card with your charger in APP.

  • Page 45: Third-Party Monitoring Portal

    Once your account is created, you will receive a notification email from notification@evchargo.com with your account password. 6.5. Third-Party Monitoring Portal In case you need to configure the wallbox with a third-party portal, follow the procedure: Turn on the charger’s hotspot: Turn on the charger's hotspot by restarting the power.
  • Page 46 Once logged in, click on Network Setting. Finally, change the endpoint to the one for the third-party portal and press Confirm. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 46/69...

  • Page 47: Dynamic Load Balancing

    7. Dynamic Load Balancing In the single charger scenario, the charger supports dynamic load balancing. By integrating a Current Transformer (CT) or a Meter or a meter & three CTs, the charger can dynamically adjust its charging power to ensure that the electrical system remains within the capacity limits and not overload.

  • Page 48: Supported Ev Chargers

    We will introduce the implementation of load balancing from five key aspects: ✓ The charger supporting load balancing in our company ✓ The required accessories and specifications ✓ The scenarios where the load balancing is applicable. ✓ The hardware wiring ✓...

  • Page 49: Specifications

    One meter Total current ＜ Three current ZVM-CARO-METER-02 150A transformers Three phases 7.1.4. Specifications ZVM-CARO-METER- ZVM-CARO-MATAER- Model No. ZVM-CARO-TA Voltage range 3x230V/400V Consumption <10VA(Single phase) <10VA(Single phase) ＞ 2M Ω ＞ 2M Ω Impedance Accuracy class Error ±0.2% Error ±0.2% Input current 3x10(80) Frequency...

  • Page 50: Hardware Wiring

    Working altitude <2000m Warranty 2 years 7.1.5. Hardware Wiring Caro_Single phase Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 50/69...
  • Page 51 Type B If the terminal block does not correspond to the one indicated on the wallbox, refer to the following procedure: STEP 1 Loosen the two screws with a flat screwdriver (flat head: 2 mm). STEP 2 Insert the red cable and the white cable into the corresponding holes Manual of 08/01/2024 Rev.
  • Page 52 STEP 3 Tighten the two screws with the flat screwdriver (flat head size: 2mm) to crimp the two wires. STEP 4 Unscrew the waterproof cap and remove the rubber cap. STEP 5 Pass the wire connected to the CT jack through the center hole of the waterproof cap.
  • Page 53 Once the turret has been unscrewed, lift the board slightly to be able to insert the connector into the indicated pins. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 53/69...
  • Page 54 STEP 7 Make the connection on the marked terminal Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 54/69...

  • Page 55: Caro_Three Phases_ Meter

    Caro_Three phases_ Meter Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 55/69...
  • Page 56 type B If the terminal block does not correspond to the one indicated on the wallbox then refer to the following procedure: STEP 1 Loosen the two screws with a flat screwdriver (flat head: 2 mm). STEP 2 Insert the brown cable and the black cable into the corresponding holes Manual of 08/01/2024 Rev.
  • Page 57 STEP 3 Tighten the two screws with the flat screwdriver (flat head size: 2mm) to crimp the two wires. STEP 4 Unscrew the waterproof cap and remove the rubber cap. STEP 5 Pass the wire connected to the CT jack through the center hole of the waterproof cap.
  • Page 58 Once the turret has been unscrewed, lift the board slightly to be able to insert the connector into the indicated pins. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 58/69...
  • Page 59 STEP 7 Make the connection on the marked terminal Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 59/69...

  • Page 60: Caro_Three Phases_Meter + Ct

    Connect pin 21-22 of the meter with the brown and black cable respectively. Caro_Three phases_Meter + CT Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 60/69...
  • Page 61 type B If the terminal block does not match the one indicated on the wallbox then refer to the procedure indicated above Caro_trifase _meter. Manual of 08/01/2024 Rev. 1.0 “User Manual EV CHARGER CARO 1PH 7kW 3PH 11kW” 61/69...

  • Page 62: Software Configuration

    7.2. Software configuration 7.2.1. Configured via APP After completing the hardware wiring, you also need to configure it within the APP. Accessing Settings: Scroll down in the charging page of Evchargo app, find "Charging mode", as shown: Choose the monitoring method based on the accessories you choose to achieving load balancing.

  • Page 63: Configured Via Ap Mode

    For the use of the monitoring portal, please refer to the dedicated documentation on the website http://www.zcsazzurro.com/. In the section on charging stations see the document "User Manual Evchargo Portal" 7.2.2. Configured via AP mode AP Mode, also known as Access Point Mode, is a versatile wireless networking feature that enables devices like EV charger to function as Wi-Fi access points, establishing a dedicated hotspot.
  • Page 64 Charging completed Steady green. No Network/Not Cycle: The green light is on for 1s, followed by the yellow Connected to Server light on for 1s, then off for 3s. Bluetooth lock Cycle: Flashing: on for 4s, then off for 1s. Scheduled charging Cycle: Rapid flashing: on for 2s, then off for 2s.

  • Page 65: Troubleshooting And Maintenance

    9. Troubleshooting and maintenance This section contains information and procedures on how to troubleshoot any faults and errors 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 Evchargo APP. 2) If the charging station does report any errors, perform the following checks: Is the device located in a clean, dry and properly ventilated place? Are the cables correctly sized and as short as possible?

  • Page 66: Troubleshooting Technical Faults

    If the fault persists after the restart, contact technical Other causes support The indicator flashes red The voltage or frequency of the Please try again 10 minutes and yellow alternatively gird is unstable later Note: If the above problems cannot be resolved, contact Zucchetti Centro Sistemi Spa 9.2.

  • Page 67: Maintenance

    Yellow on for 2s, followed by the Smart meter red flashing 4 times (on for communication 500ms, off for 500ms), then 3s failure off. Yellow on for 2s, followed by the Please contact Current red flashing 5 times (on for after- sales transformer (CT) 500ms, off for 500ms), then 3s...

  • Page 68: Storage And Transportation

    Keep the charger Do not hit or press hard on the case. If the case is damaged, intact. please contact customer service. If there is water or moisture inside the charger, you must Avoid letting immediately switch off the electricity supply to avoid moisture or water immediate danger.

  • Page 69: Warranty

    10. 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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