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ZCS AZZURRO DC 30K CORE Series User Manual

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Serie DC 30K CORE
User Manual
Manuale del 09/02/2024 Rev. 0.0 "Manuale Utente EV CHARGE DC 30K CORE"
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Summary of Contents for ZCS AZZURRO DC 30K CORE Series

  • Page 1 Serie DC 30K CORE User Manual Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 1/76...

  • Page 2: General Instructions

    (including software, etc.), in any form or by any means without the consent of Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right of final interpretation. This manual is subject to change based on feedback from users, installers, or customers.

  • Page 3: Table Of Contents

    Summary 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. Interior view ..........................16 Checks before installation ........................17 3.1.
  • Page 4 6.2. Connect the charging station to a third-party portal ..............54 6.3. Connect the charging station to the Evchargo APP ..............56 6.4. Configure RFID cards ........................59 Operations ............................... 60 7.1. Descrizione indicatori ........................60 7.2. LCD Information ........................... 60 7.3.

  • Page 5: General Information

    Foreword General information Please read this manual carefully before proceeding with installation, use or maintenance. This manual contains important safety precautions that must be followed and adhered to when installing and maintaining the equipment. Scope This manual describes the assembly, installation, electrical connections, commissioning, maintenance and troubleshooting of the charging station: Keep this manual so that it can be accessed at all times.
  • Page 6 Note: Provides important tips for the correct and optimal operation of the product Note Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 6/76...

  • Page 7: Preliminary Safety Instructions

    1. Preliminary Safety Instructions If you have problems or doubts in reading and understanding the following information, please contact Zucchetti Centro Sistemi S.p.A. through the appropriate channels. Note 1.1. Safety Instructions It mainly introduces the safety instructions to be followed when installing and using the equipment. Before installing and using the equipment, read and understand the instructions in this manual and familiarize yourself with the relevant safety symbols illustrated in this chapter.
  • Page 8 Comply with the instructions in this manual and any applicable local regulations. If local regulations contravene the instructions in this manual, local regulations will apply. In the event of any conflict or contradiction between the requirements or procedures contained in this manual and local laws and/or regulations, please follow the laws and/or regulations and the requirements and processes defined in this manual and to the extent permitted by law.
  • Page 9 Wear the appropriate personal protective equipment (PPE). Do not use the charging station and contact the manufacturer promptly if the safety or safe use of the charging station is compromised. This includes, but is not limited to, the following conditions: the casing is damaged, the charging cable or connector is damaged, lightning has struck the charging station, an accident or fire has occurred on or near the charging station, water has penetrated the charging station.

  • Page 10: Transportation Requirements

    In the event of flooding, do not activate the charging station while it or the vehicle is submerged in water. Danger Children should not approach or use the charging station to avoid injury. Danger During the charging process, the vehicle's engine must always remain switched off and it is strictly forbidden to start it.

  • Page 11: Electrical Connections

    Otherwise, ZCS will not provide any warranty or assistance. Note Operation Do not use the product if it has any defects, breaks, scratches or leaks, but contact your dealer or ZCS technical service Coming into contact with the mains power supply or the terminal of the device may cause electric shock or fire! 1.

  • Page 12: Maintenance And Repair

    Se la stazione di carica non funziona correttamente: Scollegare l’alimentazione in ingresso e in uscita • Warning Take extra care when charging during a thunderstorm or in the 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, so it is strictly forbidden to do so while the system is in operation.

  • Page 13: Symbols And Icons

    1.2. Symbols and icons Introduces the most important safety symbols on the charging station. There are a number of safety symbols on the charging station. Read and understand the contents of the symbols before installation: Beware of high voltage Complies with European Standards Earth connection point Read this manual before installing the charging station Degree of protection of the device according to IEC 70 -1 (EN...

  • Page 14: Labels

    1.3. Labels Figure 2 - Labels on the charging station DO NOT remove the labels. DO NOT cover with paper, supports, cabinets, etc. Always keep them clean and legible. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 14/76...

  • Page 15: Product Overview

    2. Product Overview 2.1. Product Introduction Figure 3 – Dimensions Connector CCS2 External IP54 Boot Mode APP/RFID Installation Wall or column (optional) LED Indicator Touch screen Figure 4 – Detail Air inlet Cable input Charging connector Ethernet input Emergency stop button Air outlet Touch screen Hook...

  • Page 16: Interior View

    2.2. Interior view Tamper Detector Circuit breaker Power mode switch AC contactor Relay Switch Board Time Relay PLC converter Terminal Lock Charge Control Board Main Control Board DC Counter Gateway RFID Card Sensor Area Emergency button Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 16/76...

  • Page 17: Checks Before Installation

    3. Checks before 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. Danger • Take into account the weight of the charging station during transport and installation.

  • Page 18: Packaging Contents

    Packaging Contents N° Component Charging station Mounting bracket 60 x M8 Anchor Bolt 100 x M12 Anchor Bolt RFID Activation Card 16 x Viti M6 Expansion tube Self-tapping screw Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 18/76...
  • Page 19 Cable support Pillar Ring Power module Cable ties Inner triangle wrench Declaration of conformity User Manual Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 19/76...
  • Page 20 Guarantee Table 2 – Package Contents The 100 x M12 Anchor Bolt and Pillar are optional, so please make sure you have selected them, otherwise delivery will not include these two items. Note Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 20/76...

  • Page 21: Installation Tools

    3.2. Installation tools The following installation tools are required for the installation of the charging station and electrical connections; therefore, they must be prepared before installation. N° Instrument Function Screw and unscrew the screws of Phillips screwdriver the different connections Screw and unscrew the screws of Slotted screwdriver the different connections...
  • Page 22 Remove the outer sheath of the Wire Stripping Tool cables RJ45 connector crimping tool Crimp the cables Insert the expansion plugs into the Rubber hammer wall holes Check the voltage and current Multimeter values Make marks on the wall for greater Marker fixing accuracy Tape measure...

  • Page 23: Handling The Charging Station

    3.3. Handling the charging station 1. Open the package and remove the polystyrene protective cover, insert your hands into the slot and grasp the device; 2. Lift the charging station out of the packaging and bring it to the installation position, then remove the polystyrene protectors.

  • Page 24: Recommended Installation Distances

    3.5. Recommended installation distances It is recommended to install the charging station 1.2 m above ground. The distance between two chargers must be at least 1 m. It is recommended to install the charging connector holder 1m above ground. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 24/76...

  • Page 25: Installation

    4. Installation Disconnect the power supply before proceeding with installation • work Pericolo 4.1. Preparation Step 1: Preparing the site. Ensure the space around the charging station for at least 1 meter on all sides free of objects. Step 2: Properly prepare the installation foundations with a concrete structure. Step 3: Make sure the vertical tilt angle does not exceed 5% 4.2.
  • Page 26 Four marks can be made in all, based on each of the holes in the four corners of the mounting bracket, but it is recommended to make them symmetrically. Note Step 2: Use the power drill to drill four holes on the marks made in the previous step. Step 3: Use a hammer to insert the entire anchor bolt into the holes.
  • Page 27 Step 4: Install the wall plate. Hang the mounting bracket by inserting the exposed screw into the hole in the mounting bracket. Step 5: Insert the nuts onto the screws to securely fasten the mounting bracket. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 27/76...
  • Page 28 Step 6: Hang the charging station and tighten the fixing bolt on both sides. Step 7: To hang the charging station, insert the ends of the two parallel iron bars of the mounting bracket into the hooks on the back of the charging station so that they fit together. Tighten the charging station with two screws.
  • Page 29 Step 8: Loosen the 8 screws on the power module cover. Step 9: Use a slotted screwdriver to turn the "arrow" knob so that the arrow points to the number 0. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 29/76...
  • Page 30 Step 10: Gently place the power module in the cabinet. Step 11: Close the lid. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 30/76...
  • Page 31 Step 12: Put the 8 screws into the holes in the cover and tighten the screws. Step 13: Place the cable mount on the wall, holding it vertically and level, and make four marks at the holes on the cable mount. Manuale del 09/02/2024 Rev.
  • Page 32 Step 14: Drill four holes with a power drill on the marks made in the previous step. Step 15: Push the entire anchor bolt into the holes with a hammer. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 32/76...
  • Page 33 Step 16: Unscrew the nuts counterclockwise with an adjustable wrench. Step 17: Hang the cable holder by inserting the exposed screws into the holes in the cable holder. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 33/76...
  • Page 34 Step 18: Screw the nuts onto the screws to securely attach the cable mount. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 34/76...

  • Page 35: Column Installation (Optional)

    4.3. Column installation (optional) The installation of the fast charging station can be carried out on solid ground, which can be a concrete foundation or a concrete floor. When sizing foundations, it is recommended to perform a static load capacity analysis in accordance with the relevant standards. Prepare the concrete foundation.

  • Page 36: Install The Column And Charging Station

    4.3.1. Install the column and charging station Step 1: Align the holes in the column with the concrete foundation nuts, then tighten the screws. Step 2: Place the charging station on the pedestal bracket, as shown, and match the ten holes in the pedestal with the ten holes at the bottom of the charging station.
  • Page 37 Step 3: Insert the screws into the holes and tighten them to secure the charging station securely to the column. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 37/76...

  • Page 38: Install The Cable Mount

    4.3.2. Install the cable mount Step 1: Loosen the four screws on the right side of the column and align the holes in the socket holder with the socket support installation holes on the column. Step 2: Tighten the screw clockwise to securely attach the socket mount. Manuale del 09/02/2024 Rev.

  • Page 39: The Cable Route

    4.3.3. The cable route Step 1: The cable will be laid underground, then it will pass through the hole on the left side of the concrete foundation and exit through the hole at the top of the foundation to pass through the column and exit through the hole on the left side of the column.
  • Page 40 Step 2: Use the power drill to drill four holes on the marks made in the previous step. Step 3: Push the entire anchor bolt into the holes with a hammer. Step 4: Loosen the nuts counterclockwise with an adjustable wrench. Manuale del 09/02/2024 Rev.
  • Page 41 Step 5: Insert the four exposed screws into the four holes in the column. Step 6: Insert the nut onto the screw to securely fasten the column. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 41/76...
  • Page 42 Step 7: Column installation completed. Step 8: Align the ten holes in the column with the ten holes on the bottom of the charging station. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 42/76...
  • Page 43 Step 9: Tighten the ten screws to secure the charging station securely on the column. 1. For the installation of the mount, refer to the "Installing the Mount" section in the wall installation. Attention Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 43/76...

  • Page 44: Power Module Installation

    4.4. Power Module Installation Step 1: Remove the side panel (store the screws properly) Step 2: Insert the power module and tighten 4 x M4 x 12mm screws. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 44/76...
  • Page 45 Step 3: Replace the side panel. Caution: The LED indicator should be kept at the top. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 45/76...

  • Page 46: Wiring

    4.5. Wiring 4.5.1. Connect the power cord Figure 7 – Wiring Step 1: Remove 90 mm of the cable sheath. Remove 10 mm of the wire sheath. Lay out the exposed copper wires and insert them into the ferrules. Crimp the terminals with the crimping tool. Note: The recommended wire diameter is 16mm2 Manuale del 09/02/2024 Rev.
  • Page 47 Step 2: Use the wrench to loosen the strain relief at the bottom of the cabinet and insert the cable into the strain relief. Remember that the circuit breaker is OPTIONAL; The diagrams below show the two different wiring options. Loosen the screws on the terminal block as indicated, then insert the crimped ferrule wires into the ports and tighten the screws.
  • Page 48 Step 4: Without circuit breaker Step 5: Connect the PE cable. Loosen the screws with a slotted screwdriver. Insert the crimped PE cable with ferrule into the port and tighten the screws. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 48/76...

  • Page 49: Ethernet Cable

    4.5.2. Ethernet cable If Ethernet connection mode is set, then follow the instructions below. Step 1: Remove the cable and wire sheath with the wire stripping pliers. Step 2: Insert the wires into the RJ45 connector and crimp the wires with the crimping tool. Manuale del 09/02/2024 Rev.

  • Page 50: External Protective Equipment

    Step 3: Connect into the port indicated by the arrow and secure the cables with a cable tie. I also changed the photos below) 4.6. External protective equipment The charging station is equipped with a residual current device (RCD) to detect any current faults. It is also equipped with a detection system for DC components above 6mA.

  • Page 51: Commissioning: Configure The Network For The Charging Station

    Through EVchargo APP, with which you simply install the APP on your smartphone and perform the steps for configuration Through the EVchargo portal, with which you must send a written request to the ZCS team indicating the name of the company, the name of the account and the email with which you want to configure the account.
  • Page 52 Step 2: Click on Step 3: Set up Wi-Fi or Ethernet. After logging in, you will have access to the following interfaces: If you choose the Wi-Fi connection mode, search for the network to which you want to connect the charging point and enter the relevant password if present to make the connection.
  • Page 53 Controllare che l’indirizzo della piattaforma indicato sotto corrisponda Evchargo Cloud Platform Address: wss://ocpp16.evchargo.com:33033 (The following corresponds to the serial number of the charging station) Attention Once you press on confirm, the charging station will automatically restart, ending communication between the mobile phone and the charging point.

  • Page 54: Connect The Charging Station To The Evchargo Portal

    6.1. Connect the charging station to the Evchargo portal You can ask our team through the customer support service, to activate an account on the Evchargo Cloud platform, by indicating to us: the name of the account the name of the company email with which you want to register.
  • Page 55 Connect to the charger hotspot: Turn on your smartphone's Wi-Fi and connect the charger hotspot. If you can't connect, try using airplane mode. The name of the Wi-Fi hotspot starts with the SN number of the charger, which is "SN..." . The password is admin123 Access Open the browser on your smartphone and enter 192.168.4.1 in the address bar.

  • Page 56: Connect The Charging Station To The Evchargo App

    If you choose to use the charging station for private use, then it is recommended to choose the configuration through the Evchargo application, so you do not need to contact the ZCS service to make a request. The app is available for Apple and Android devices.
  • Page 57 If you are setting up near the charging station then you can select on Check nearby, otherwise you can manually add or scan the QR code on the wallbox label. Select ZCS Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE”...
  • Page 58 By selecting WiFi you will be asked to choose the network and enter the specific password. If the configuration was successful, you will have to display the charging station on Available as in the screenshot below. To start charging from the APP press on Start, to stop charging press on Stop. Manuale del 09/02/2024 Rev.

  • Page 59: Configure Rfid Cards

    6.4. Configure RFID cards To add RFID cards press on Me, Card Management, Add a Card. Once added, the identification code above will appear. Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 59/76...

  • Page 60: Operations

    7. Operations Once the charging station is installed, follow the next steps to test the operation. 7.1. Descrizione indicatori Indicatore Descrizione The yellow indicator stays on The charging connector has been inserted. The green indicator stays on Stand-by The red indicator stays on Error Flashing yellow indicator Alarm (charging connector has been inserted)
  • Page 61 Plug the connector into the EV's charging socket and select the start modes. • With Evchargo App: Use the app to start the charging session. • With RFID card: Use the configured RFID card to start the charging session. Select boot mode before the remaining operating time ends, otherwise the operation will fail and the user will have to remove the connector before inserting it again.

  • Page 62: Pre-Boot Checks

    The user can end the charging session in the same way as it was started: • RFID Card • APP Evchargo Payment information as shown. 7.3. Pre-boot checks The operation of this charging station must be carried out in accordance with the test instructions below.
  • Page 63 After transportation and installation, check the following: Controls Execution Perfect mechanical condition of all installed Mechanical visual inspection devices. Random or complete verification of tightening torques on terminals and mechanical screw Screw connections, tightly tightened connections. Check if the grounding takes into account the specific conditions of the site Earthing system as well as the standards in force.

  • Page 64: Checks Before First Power-Up

    7.4. Checks before first power-up Outcome Controls Missing External visual inspection of the charging station (damage, defects) Stability verification Inspection of cable connections Fuse inspection Visual inspection of screw connections Is the inside of the charging station clean and free of condensation? Verification of air and leak lines Verification of buffer filters...

  • Page 65: Annex - Outline Of The Working Principle

    8. Annex - Outline of the working principle Circuit breaker Main Control Panel Voltage Limiter DC Control Panel Auxiliary switching power supply Power Module Charging cable K1/K2 DC contactor Screen Fuse Card reader Derivation Emergency stop DC Wattmeter Input control Scheda luce LED COLOR DESCRIPTION...

  • Page 66: Indicatore Led

    9. Indicatore LED There are 2 LED indicators at the interface of the charging station. State Description LED status Power on, no connector Standby Green light on normally inserted Flashing yellow light at Connector inserted, no charge Ready to charge still started 1S intervals Flashing green light a...

  • Page 67: Technical Datasheet

    10. Technical Datasheet Manuale del 09/02/2024 Rev. 0.0 “Manuale Utente EV CHARGE DC 30K CORE” 67/76...

  • Page 68: Troubleshooting And Maintenance

    Solo documento principale. 11. Troubleshooting and maintenance 11.1. Troubleshooting This section contains information and procedures on how to resolve any errors and faults that may occur during the operation of the charging station. If you encounter any problems, do the following: 1.
  • Page 69 Solo documento principale. Check the inbound frequency from the backend. E005 Input frequency too low If the frequency is below 50Hz for a short time, wait until the mains supply returns to the normal voltage range. E007 DC leakage current is abnormal Check if the emergency button has been pressed, then E008 Emergency stop...
  • Page 70 Solo documento principale. The set required current exceeds E025 the maximum output current of the charging station E027 DC Connector K1/K2 Error E031 DC leakage current is abnormal The voltage during the insulation E032 test phase did not meet the requirements.
  • Page 71 Solo documento principale. E041 Power module address error The output of the power module E043 is short-circuited The power module is not E044 enabled, it is not available The main control board is E048 overheated The output voltage exceeds the E053 maximum allowable voltage of 110% for 200ms.

  • Page 72: Maintenance

    Solo documento principale. E056 Screen communication error Communication error between E057 the main control board and the control board The insulation resistance is too E059 low and charging is not allowed Excessive deviation of the required voltage from the E061 voltage of the charging connector (>...
  • Page 73 Solo documento principale. For the safe operation of the fast charging station, regular maintenance or checks of the safety devices are required. All the points listed below are considered mandatory and must be carried out by the operator according to the intervals indicated. The following table gives an overview of the maintenance work required.
  • Page 74 Solo documento principale. Random or complete verification of tightening torques on terminals and mechanical screw Screw and Latch Every day connections. Check if the fastener is stuck or damaged and if the fixing screws are loose. Verify that the surge protector Overvoltage protection Every six months is working properly...

  • Page 75: Disassembly And Disposal

    Solo documento principale. 12. Disassembly and disposal The packaging materials are environmentally friendly and can be recycled. Therefore, they can be disposed of in special recycling bins in accordance with local waste disposal regulations. However, the charging station may not be disposed of as household waste, but must be treated as special waste. It must be disposed of at authorized facilities to dispose of electrical and electronic products.

  • Page 76: Guarantee

    Solo documento principale. 13. Guarantee Zucchetti Centro Sistemi SpA offers a 2-year warranty from the date of installation of the charging station, upon registration on the https://www.zcsazzurro.com/it/estensione-garanzia website. During the warranty period, Zucchetti Centro Sistemi S.p.A. guarantees the normal operation of the charging station.

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