ZCS ZUCCHETTI ZVD-60K-PRO User Manual

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EV CHARGER DC POWER

ZVD-60K-PRO

ZVD-120K-PRO

User Manual

Manual of 23/02/2024 Rev. 0.0 "User Manual EV CHARGE DC 60K/120K POWER"

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Page 1 EV CHARGER DC POWER ZVD-60K-PRO ZVD-120K-PRO User Manual Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 1/52...
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 Preliminary safety instructions ......................... 6 1.1. Safety instructions ......................... 6 1.2. Symbols and icons ........................12 1.3. Labels ............................13 Installation ............................... 14 2.1. Product Overview ........................14 2.2. Checks before installation......................15 2.2.1. Installation tools .......................... 18 2.3.
Page 4 6.1.1. Start Charging ..........................40 6.1.2. Stop Charging ..........................40 6.1.3. Charger Setting ..........................40 Appendix-Working principle diagram for ZVD-120K-POWER ..............41 LED Indicator ............................42 Datasheet ..............................43 Troubleshooting and maintenance ....................44 10.1. Troubleshooting ........................... 44 10.2. Maintenance ..........................48 Dismantling and disposal ........................
Page 5 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 6: Preliminary Safety Instructions
Note: provides important tips on the correct and optimal operation of the product Note 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.
Page 7 Follow the instructions in this manual exactly. Only perform any services as installation engineer or use the DC charger when you are fully qualified to do so. 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.
Page 8 Ensure that the grid's load capacity corresponds to the DC Charger. Ensure that the wiring within the DC Charger is not damaged and cannot become caught when the cabinet is opened or closed. Make certain that no water can enter the cabinet. Protect the DC Charger with the safety equipment and procedures specified by local regulations.
Page 9 Do not use the charger in case the product has defects, crack, abrasion, bare leakage and so on. Please contact the working staff in case of above conditions. Danger Please do not attempt to disassemble, repair, or modify the charger. If there is a need for maintenance or modification, please contact the aftersale service.
Page 10: 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 11: 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 12: Symbols And Icons
Before performing any repairs, disconnect the charging station from • the power supply (AC side) and from the data connection to the transmission gate. After switching off the DC switch, wait 5 minutes before carrying out • any repairs or maintenance on the charging station Danger The charging station should start working again after any faults have •...
Page 13: Labels
1.3. 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 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 13/52...
Page 14: Installation
2. Installation 2.1. Product Overview Figure 3 – Detail Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 14/52...
Page 15: Checks Before Installation
DO NOT install the charging station near flammable materials. • DO NOT install the charging station in an area where flammable or • explosive materials are stored. Danger Take into account the weight of the charging station during • transport and installation. Choose an appropriate mounting position and surface.
Page 16 Contents of the packaging Part Charger M12 Screw RFID card Power module Key for opening the front door Key for right door (for adding power modules Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 16/52...
Page 17 Declaration of Conformity User Manual Warranty Table 2 – Package contents Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 17/52...
Page 18: Installation Tools
2.2.1. 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 Cross Screwdriver Tight the screws (PH2x150mm, PH3x250mm) Drill To drill scre holes Tight the bolts Insuleted Torque Wrench panner Tight the bolts and nuts...
Page 19: Prepare Tools
Measuring tape To measure distances To make sure the bracket is Level level ESD gloves Protective clothing Safety goggles Protective clothing Table 3 – Installation tools 2.3. Prepare tools Personal Protective Safety helmet Protective gloves Insulated shoes equipment Insulated security torx torque insulated torque Hammer drill and...
Page 20: Prepare Cable
2.4. Prepare cable Cable type Operating current Cross-sectional area 190A (DC120kW) 95~120mm2 AC Input power cable (three- phase five wire) 96A (DC (60kW) 50~70mm2 It is important that all cables used are suitable for outdoor use 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 21: Recommended Sizes For Installation
2.5.1. Recommended sizes for installation The base shall be built according to the requirements. It is recommended that the base be 200mm higher than the road surface, 100mm larger than the outside of the cabinet for each measurement ratio before, during and after the cabinet, and threading holes shall be reserved. Install Holders According to the installation size drawing of charging pile base, make bolt holes in the base and the recommended depth is 100mm, the diameter of Φ16mm.
Page 22 Connect Cables The power supply cables go through the input cable inlet at the charger's bottom, and connect to the corresponding L1, L2, L3, N and PE terminals inside the charger. Please note that L1, L2, L3, N correspond to R, S, T, N phases. Placement distance Distance between charger rear and wall ≥...
Page 23: Prepare Concrete Foundation
2.5.2. Prepare concrete foundation The concrete foundation is made up of two pieces that are cast in cement and are fixed and joined with steel bars. Please note that the tubular nuts with threads should be embedded while preparing the foundation. Step 1: Step 2: Manual of 23/02/2024 Rev.
Page 24: Installation
3. Installation Please disconnect the power supply before proceeding with • installation work Danger 3.1. Preparation Step1: Electrical product should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by the manufacturer for any consequences arising out of the installation of this product.
Page 25: Installation
3.2. Installation Step1: Loosen the screws that hold the front and rear panels in place at the bottom of the charger to remove the panels. Step2: Use the forklift to lift and carry the charger, and place it onto the concrete foundation. Manual of 23/02/2024 Rev.
Page 26 Step3: Secure the charger to the concrete foundation with four M12 screws. Place the front and rear panels in place, fasten them with screws. Step4: Each power module has a number disc. Find it and use a flat-head screwdriver to rotate the arrow on the disc so that it points to the designated number, as indicated in the above figure.
Page 27: Wiring
3.3. Wiring 3.3.1. Connect power cable Before wiring, please make sure that the power has been cut off. • Attention Step1: he cable is routed in from A and gets out from B to comes into the charger. Step2: Loosen the screws on the terminals. Step3: Connect the cable to the correct terminals and tighten the screws clockwise.
Page 28: Connect Communication Cable
3.3.2. Connect communication cable On the gateway PCB, plug the RJ45 connector for Ethernet cable to the appropriate ports. Note: The gateway PCB can be found at section 3 product overview. Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 28/52...
Page 29: Commissioning: Configure The Network For The Charging Station
4. Commissioning: Configure the network for the charging station The charging station can be put into operation through the following ways: Through EVchargo APP, with which you simply install the APP on your smartphone and perform the steps for configuration Through a third-part platform To configure the Wi-Fi or Ethernet of the charging station, you must use AP mode.
Page 30 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 31 Attention Once you press on confirm, the charging station will automatically restart, ending communication between the mobile phone and the charging point. Your mobile phone can now automatically connect to other Wi-Fi hotspots, preventing you from accessing the network configuration interface. As a result, before entering the network configuration interface, make sure that your mobile phone is connected to the Wi-Fi hotspot of the charging station.
Page 32: Connect The Charging Station To The Evchargo Portal
4.1. 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 33 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 34: Operations
5. Operations 5.1. Indicator description Indicator Description Yellow indicator keeps on The charging connector has been plugged in Green indicator keeps on Idle Red indicator keeps on Faults Yellow indicator flashes Alarm (charging connector has been plugged in) Green indicator flashes Alarm (idle) 5.2.
Page 35 Plug the connector A or B in and choose the start modes. • With Evchargo App: use the app to start charging session (please scan the Evchargo APP instruction below). • Use a RFID card to start the charging session. Manual of 23/02/2024 Rev.
Page 36 Evchargo App Instructions If App is chosen, then have a look on the user manual of App. Note During charging session, and the charging details displayed. Make payment after the charging finished. The user can terminate the charging session by scanning the QR code or by the RFID card then make payment by adding the bank card.
Page 37 Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 37/52...
Page 38: Checks Before Initial Startup
5.3. Checks before initial startup The operation of this DC charger must be performed in accordance with the test instructions outlined below. All of the instructions given below are required and must be followed by the operator of the DC charger.
Page 39: Checks Before Switching On For The First Time
5.4. Checks before switching on for the first time Checks Result Deficient External visual inspection of the charger (damage, defects) Checking the stability Inspection of the cable connections Inspection of the fuses Visual inspection of the screw connections? Is the inside of the charger clean and free from traces of condensation? Checking the air and creepage distances Checking the filter mats...
Page 40: Operation Instruction
Check the charging connector (dry) 6. Operation Instruction 6.1.1. Start Charging Park EV near to the charger, and plug the charging connector into the EV. After plug-in, please check the connector is correctly and tightly connected. With appropriate connection, the charger will start charging the EV.
Page 41: Appendix-Working Principle Diagram For Zvd-120K-Power
7. Appendix-Working principle diagram for ZVD-120K-POWER QF1/QF2 Circuit breaker Main control panel Lightning arrester KZ1/KZ2 DC control panel Auxiliary switching DY1/DYF power supply Fan adapter P12/P13 AC filter MK1/MK2/MK3/MK4 Power module LED light board K1/K2/K3/K4/K5/K6 DC contactor Display screen FU1/FU2 Fuse Card reader FL1/FL2...
Page 42: Led Indicator
PWM line Feedback PLC communication line DC power line (undervoltage) 8. LED Indicator There are 2 LED indicators next to charger interface. State Description LED Status Power-on, and no connector Standby Green light normally on plug-in Connector plug-in, and charging Yellow light flashing at the Ready to charge interval of 1S...
Page 43: Datasheet
9. Datasheet Manual of 23/02/2024 Rev. 0.0 “User Manual EV CHARGE DC 60K/120K POWER” 43/52...
Page 44: Troubleshooting And Maintenance
Solo documento principale. 10. Troubleshooting and maintenance 10.1. Troubleshooting 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 the information panel of the device.
Page 45 Solo documento principale. Over Check the surrounding conditions of chargers installed whether there is heating temperature device nearby. Make sure environmental temperature is under 60℃. Check whether the output voltage is within parameters setting range. If not, please Output over- check whether the output voltage/current is too high, or the parameters setting is voltage reasonable.
Page 46 Solo documento principale. E014 Relay adhesion E015 The PE of the charging connector is not grounded. E016 The L1 line and N line at the input side are connected reversely E017 AC RCD circuit error E022 Meter communication failure E023 AC CP voltage error E024 The set demand voltage exceeds the maximum output voltage of the charger E025 The set demand current exceeds the maximum output current of the charger E027 The DC connector K1/K2 error...
Page 47 Solo documento principale. E044 The module is not enabled,unavailable E048 The main control board is overtemperature E053 The output voltage exceeds the maximum allowable voltage by 110% for 200ms. E054 Door access control failure E055 Card reader communication error E056 Screen communication error E057 Communication failure between main control board and the control board E059 The insulation resistance is too small and charging is not allowed Excessive deviation of demand voltage from charging connector voltage (output >...
Page 48: Maintenance
Solo documento principale. 10.2. 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 49 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 50 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” 50/52...
Page 51: Dismantling And Disposal
Solo documento principale. 11. 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 52: Warranty
Solo documento principale. 12. 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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