ZAPTEC Pro User manual

Zaptec Pro
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Zaptec
Installation
Manual

2
English
Installation Manual for Zaptec Pro
This installation manual contains the information necessary to
safely install and control the charging station.
Zaptec recommends that anyone who installs our products
completes a training course for Zaptec charging systems.
The installation technician/service partner is always the first point
of contact for support. For contact details for Zaptec‘s technical
support, see zaptec.com.
A user manual is included in the Zaptec Pro box.
You will find the most recent version at Zaptec.com/support.
See the last page for the version number of the manual.
This installation manual includes:
1. Safety instructions 5
2. Description of the Zaptec Pro system 6
3. Technical Specifications 7
4. Installation 9
5. Troubleshooting 19
6. Storage and Maintenance 21
7. Guarantee 21
8. Support and Repairs 21

3
English
1. Safety instructions
WARNING!WARNING!
Before using or maintaining this product, it is important to read the following
safety instructions. Failure to follow and implement all the instructions and
procedures stipulated in this installation manual will invalidate the warranty and
cause Zaptec Charger AS to waive all liability and claims for compensation.
!
Read through the instructions carefully and familiarise yourself
withtheequipment before you start using it.
!
This equipment may only be installed, repaired and maintained by qualified
personnel. Repairs must be carried out by Zaptec or a pre-approved
workshop.
!
All applicable local, regional and national regulations must be followed
wheninstalling, repairing and maintaining the equipment.
!
Do not use a product which is damaged in any way. See the information
inthechapter on Support and Repairs.
!
Only use approved cabling for the installation.
!
Do not insert foreign objects into the Type 2 socket.
!
Do not use high-pressure washers to clean the Zaptec Pro. Follow
theinstructions in the chapter on Storage and Maintenance.
!
Do not install in a location which is exposed to direct sunlight.
!
Adapters are permissible – A conversion adapter from the EVSE plug
mustonly be used if specified and approved by the vehicle manufacturer
orEVSEproducer.
!
Do not insert test probes, wires or anything else into the quick-release
connector on the back plate. Voltage tests should be performed directly
onthe terminal screws or using a female connector.
!
Read the guarantee at zaptec.com/guarantee or contact Zaptec Support
andrequest a copy.

4
English
2. Description of the Zaptec Pro system
Use all available capacity
The power is shared dynamically across all the charging
stations. Enables over 100 electric vehicles to be charged
in one day, via a single 63A* circuit breaker. Charge at up
to 22kW on all charging stations.
Unique scope for scaling with a single circuit
andpower cable
Communication between the charging stations and the
cloud solution passes through the same power cable.
This shared infrastructure makes it possible to start
with a few charging stations and expand the system as
and when necessary. Scaling an existing installation will
therefore not require any extra work or investment in
electrical infrastructure.
Fair use through RFID or Zaptec App
A built-in electricity meter accurately records
energy consumption, which can then be allocated
toauthorised users.
* With three-phase connection and typical charging usage over 24 hours.
Safety in accordance with the highest standards
Fully-rated Type 2 charging socket, circuit breaker,
electronic earth fault protection and temperature sensors
are built into the charging station. This ensures safety
forboth the user and the power grid.
Future-proof and intelligent charging solution
Combines power electronics, built-in software and a
cloud-hosted portal for configuration, monitoring and
control. The solution is future-proof, with software updates
delivered over-the-air to the charging station.
4G 4G 4G 4G
4G
kW
kr
199 kWh
2 3 3
4
Zaptec
4G
Zaptec

5
English
3. Technical Specifications
Mechanical and installation
Parameter Test condition Min Typ Max Unit
Dimensions H: 392 W: 258
D: 112
mm
Weight Including backplate 5 kg
Altitude 2000 m
Input cable cross section 2.5 10 mm²
Input cable diameter 13 18.5 mm
Degree of protection IP54
Noise emission With fan running 47.5 dBa
Charging mode Mode 3, case B
Mechanical strength IK10
Pollution degree Installation
environment
4
Support for ventilation According to EN
61851-1 6.3.2.2
No
Access According to EN
61851-1 5.4
Restricted and non-restricted access
General
Parameter Test condition Min Typ Max Unit
Rated voltage (Un) Phase-Neutral 207 230 253 V
Phase-Phase 360 400 440
Rated current (In) 32 A
Rated frequency 50 Hz
Standby power consumption 3 W
Ambient operating temperature -30 40 °C
Maximum charging power
TN 3 phase @ 32 A 22
kW
TN 1 phase @ 32 A 7.4
IT 3 phase @ 32 A
(Norway only)
12.7
IT 1 phase @ 32 A
(Norway only)
7.4
Protection class I
Overvoltage category III

6
English
Connectivity
Protocol Supported standards
4G LTE Cat M1
Wi-Fi 802.11b/g/n (2.4 GHz)
Bluetooth Bluetooth v5.1 (BR/EDR/BLE)
Powerline (PLC) HomePlug Green PHY, 10 Mbit/s
Plug and charge Hardware support for ISO15118
RFID ISO/IEC 14443 A (Type A, 13.56 MHz)
ISO/IEC 15693 (Mifare classic, 13.56 MHz)
Integrated energy meter
Parameter Test condition Min Typ Max Unit
Accuracy
Line voltage,
current, and power
factor
-2 2 %
Line voltage,
current, power
factor and
temperature
-3 3 %
Integrated RCCB
Parameter Symbol Min Typ Max Unit
Residual operating current IΔn0.03 A
Operating characteristics Type B
Making and breaking capacity Im 500 A
Residual making and breaking
capacity
IΔm500 A
Rated conditional short-circuit
current
Inc 3 kA
Rated conditional residual short-
circuit current
IΔc 3 kA
Integrated circuit breaker
Parameter Symbol Min Typ Max Unit
Manufacturer and part number Lovato P1 MB 3P C40
Rated current In 40 A
Curve C
Nominal short-circuit breaking
capacity
Icn 10 kA
For CE documentation please see zaptec.com/CE-documentation

7
English
4. Installation
Prepare for the installation in the Zaptec Portal
Only Zaptec installation technicians/service partners can add installations
in the Zaptec Portal cloud solution. New installation technicians/service
partners must contact Zaptec’s technical support via zaptec.com in order
tohave service authorisation added to their user profile. They will then
beable to add new installations.
Log on at https://portal.zaptec.com. If you wish to add a new Zaptec Portal
installation, go to Installations and fill in the form shown below:
Name: Give the installation a name.
• Address: The address of the installation’s physical location.
• Category: Select the installation category from the drop-down list.
• Network type: Choose the appropriate power grid for the location
ofthecharging system.
• Protection for charging system: The maximum current that the installation
can use for charging. This could be a digital budget or the value of the
physical overload protection or the power switch. If the charging station
is located on a separate circuit, the maximum current per phase must
normally be set to the rating of the circuit breaker.

8
English
Add charging circuits to the installation
• Once the installation has been set up, press the “Circuits” tab
• Click on “Add circuit”
• Enter the circuit designation stated on the circuit breaker
• State the value A] for overload protection
Charging stations that receive power from this charging circuit can charge
up to the value of the charging circuit. You may wish to specify a lower value
to limit the maximum circuit current.
Add charging stations to the installation
After you have created the installation in Zaptec Portal, create circuits in
accordance with the electrical installation at the location. The charging
stations must then be added to the associated circuits.
Fill in the serial number (ZPRxxxxxx) and the name of each charging station.
The name should be the charging station’s owner, apartment number,
parking space number or some other physical identification for the exact
location of the charging station. The location of the serial number is shown in
the illustration. Charging stations illuminate green when they are online.
Serial number,
e.g. ZPR123456
The installation in the Zaptec Portal must represent the physical installation
at the location. The Zaptec Portal installation is a virtual installation in order
to balance load and phase algorithms in the charging system.

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English
Zaptec Pro
In the box
Cable entry
Supplied with the back plate
Junction box
x 1
C SmartKey Column version ZM000278
x 1
D User manual – ZM000325
x 1
E Pin
Unique PIN code to configure the device
inthe Zaptec app
Dept. Technical reference Created by Approved by
Document type Document status
Title DWG No.
Rev. Date of issue Sheet
01.08.2017
1/1
ZCS_Sealing_Cone_8mm_v1
Fredrik Ostrem
x 1
G Small cable seal (10–16mm) – ZM000180
Dept. Technical reference Created by Approved by
Document type Document status
Title DWG No.
Rev. Date of issue Sheet
01.08.2017
1/1
Untitled
Fredrik Ostrem
x 1
H Large cable seal (16–21mm) – ZM000174
Dept. Technical reference Created by Approved by
Document type Document status
Title DWG No.
Rev. Date of issue Sheet
01.08.2017
1/1
ZM000173-2
Fredrik Ostrem
x 1
I Blanking plug for cable seal – ZM000173
x 4
J Mounting nuts – ZB100049
x 1
REMOVE BEFORE
INSTALLATION
OF ZAPTEC
K Adhesive sticker to protect connections
A Front cover
– ZM000185
B Charging station –ZM000437
F Back plate with junction box
– ZM000438
Tools required for installation
x 1 x 1 x 1 x 1
T10
4 mm
7 mm
8 mm
T10
T10 Torx screwdriver
orbit
4 mm
4mm Unbrako
screwdriver or bit
7 mm
7 mm-long socket
spanner
8 mm
8 mm-long socket
spanner

10
English
3
Prepare the cable
Recommended cable is round PFXP, Powerflex
or PFSP type with diameter Ø 13–18.5 mm.
Fit the right sealing cone onto the cable before you
connect the cables to the junction box see G or H
forrightsealing diameter.
4
Wiring
To limit the risk of leaks in outdoor installations, we recom-
mend connecting the cable to the bottom of the junction
box. If this is not possible, we recommend that the device
be thoroughly sealed and checked in accordance with the
manual, and that other seals be used (Sikaflex or similar).
Location of the charging station/back plate
90–130 cm
Avoid installing the charging
station in areas which are
exposed to direct sunlight.
High temperatures in the
device will reduce the
charging rate.
The back plate must be
mounted on a flat surface.
Well-ventilated area.
Do not install the box
closeto heat sources
orinaclosedbox.
Min. 25mm
Max 6mm
Max 11mm
x 4
1
Mount the back plate
If the wall structure requires plugs/drilling, you must ensure
that dust and dirt do not get into the junction box.
Screw requirement: Head max 12mm diameter,
Head max height 6mm, length min 25mm.
2
Remove the cover on the junction box
Undo four screws and open the cover to access the
junction box.
Installing and connecting the back plate
It is important not to create any new holes in the back plate. The four existing holes must be used.
Creating new holes in the back plate will invalidate the warranty.
G Zaptec
or

11
English
5
Connecting the wires
Connect the cables in the junction box in accordance with
the electrical system at the location. See the illustration
below. The terminal blocks must be tightened to a torque
of 5 Nm.
If you install the system on a three-phase IT network,
we recommend using a 5-wire cable – in case a TN-
transformer is installed in the future. This will mean that
theneutral connection can be
made in the fuse box rather than
on each individual charging
point, which will make it easier
tocarry out future upgrades.
Zaptec Pro installations: DO THIS!
Bottom or top entry of cable
is both OK.
Zaptec Pro installations:
DO NOT DO THIS!
The Backplate rated for
63A connection but not
63A feedthrough!
This is only ok if
installation fuse is
<=40A (like in HOME
installations)
L1
L1
L1
L2
L2
L3
L3
N
N
N
PE
PE
PE
TN 1-phase
L1
L1
L1
L2
L2
L2
L3
L3
L3
N
N
N
PE
PE
PE
TN 3-phase
L1
L1
L1
L2
L2
L2
L3
L3
L3
N
N
PE
PE
PE
IT 3-phase
L1
L1
L1
L2
L2
L3
L3
L3
N
N
PE
PE
PE
IT 1-phase
TN three-phase TN single-phase IT three-phase
(Norway only)
IT single-phase
(Norway only)
Electrical connection
There are four possible connection variants, depending on whether three-phase
or single-phase is used, and whether a TN network, TT network or IT network
(Norway only) is used, as shown under or on the label on the back plate.
3. Koble ledningene i koblingsboksen i henhold til det elektriske
systemet på stedet. Vises i illustrasjonen under. Sukkerbitene
trekkes til med et moment på 5 Nm.
Hvis du installerer på 3-fas IT-nett, anbefaler vi at det benyttes 4
leder kabel i tilfelle det installeres en transformator senere for
bedre ladeytelse. Da kan den nøytrale koblingen gjøres i sikringss-
kapet heller enn på hver enkelt ladestasjon, slik at det blir enklere å
gjøre fremtidige oppgraderinger.
Check your local wiring
regulations for any additional
requirements for the safe
installation of charging points.

12
English
1
A
2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
B
C
D
E
F
A
B
C
D
E
F
Dept. Technical reference Created by Approved by
Document type Document status
Title DWG No.
Rev. Date of issue Sheet
07.12.2017
1/1
Bakplate ute innstalasjon
Fredrik Ostrem
A
A (1.5000)
Good sealing surface
Poor sealing surface
3. Koble ledningene i koblingsboksen i henhold til det elektriske
systemet på stedet. Vises i illustrasjonen under. Sukkerbitene
trekkes til med et moment på 5 Nm.
Hvis du installerer på 3-fas IT-nett, anbefaler vi at det benyttes 4
leder kabel i tilfelle det installeres en transformator senere for
bedre ladeytelse. Da kan den nøytrale koblingen gjøres i sikringss-
kapet heller enn på hver enkelt ladestasjon, slik at det blir enklere å
gjøre fremtidige oppgraderinger.
I
6
Cable seal
Seal the unused cable entry using the blanking
plugsupplied.Tighten strain relief nuts on blanking plug
and cable until secure.
Place the cable seal over the cable entry in order to seal it
properly. The cable seal must be pulled down towards the
junction box and then pushed all the way down, so that
the cone ends up in the correct position as shown below.
Visually check that the seal has a good sealing surface.
7
Screw on the junction box cover
Screw on the junction box cover. The junction box screws
must be tightened to a torque of 0.7 Nm.
Use the correct cable seal for the cable. Check the
cable dimension and select an appropriate cable
seal. Small cable seal – cable dimension 10-16.
Large cable seal – cable dimension 16-21.
8
Test the installation
To test the installation after the cover has been screwed on,
you must use the female connection. If you test directly on
the back plate, the connections will be damaged.
(Webshop reference ZB10000zz).
NB: You must not insert test-
probes into the charging station
connector as it will be damaged
by this.
Do not insert test probes, wires or anything
else into the quick-release connector on the
back plate. Voltage tests should be performed
directly on the terminal screws or using a female
connector.
7. For å teste installasjonen etter at lokket er skrudd på må du
bruke hunnkoblingen. Dersom du tester rett på bakplaten vil
koblingene bli ødelagt.
230V
9
Protect the connections
Apply the adhesive sticker to protect the connections
if you are not installing the charging station directly after.
G Zaptec
or

13
English
Insulation test
Prior to fitting the charging station to the back plate, an insulation test must
be carried out on all back plates. If this is done while the charging station is
fitted, the overvoltage protection may be triggered and this will cause the
test to fail.
If a PLC communication module is used as a communication solution, this
must be disconnected during the insulation test in order to avoid erroneous
insulation results caused by the phase coupling function of the PLC
communication module.
Do not insert test probes, wires or anything else into the quick-release
connector on the back plate. Voltage tests should be performed directly on
the terminal screws or using a female connector.
7. For å teste installasjonen etter at lokket er skrudd på må du
bruke hunnkoblingen. Dersom du tester rett på bakplaten vil
koblingene bli ødelagt.
230V
1
Remove the adhesive sticker
Remove the adhesive sticker which protects the contact
onthe junction box, if applicable.
2
Test the installation
Use the female connection to test the installation before
continuing the fitting of it. If you test directly on the back
plate, the connections will be damaged.
3
Remove the front cover
Remove the front cover using the SmartKey* special tool
supplied with the charging station, and take the front
cover off.
* To remove the front cover on a charging station
mounted on a Zaptec Column, you must use a
SmartKey Column (supplied with the column)
inorderto access the charging station.
Install the charging station

14
English
There is a gap
between the
charging station
and the back plate.
The charging
station is placed
correctly on the
back plate.
4
Position the charging station on the back plate
NB: Verify that there is no gap between the charging station
and the back plate. If there is a gap you may have used
incompatible screws to attach the back plate to the wall
(check step 1 of installing backplate).
5
Tighten the nuts
Tighten the charging station using the four supplied nuts.
The nuts must be tightened to a torque of 3 Nm.
6
Fit the front cover
Ensure that the cover for the status indicator (Z) is
correctly positioned before replacing the front cover again.
In order to replace the front cover, you must first position
the cover over the Type 2 port and then attach it to the
charging station.
x 4
J Mounting nuts – ZB100049

15
English
Switch on the power supply to the installation
• Check that the status indicator illuminates yellow, which means
thatthesystem is starting up and performing internal checks.
• Check that the status indicator changes from yellow to green
after2–3minutes.
• If the charging station illuminates purple, it is being updated.
See the chapter on troubleshooting for more information
if the status indicator illuminates a different colour.
Activate the charging station
• Before you begin, install the Zaptec app from the App Store (Apple) or
Play Store (Android) and make sure Bluetooth is enabled. If you have not
already done so, register as a user using the app and log in.
• From the Dashboard, tap the settings symbol at the top-left of the screen
Stand close to the charging station you wish to configure.
• Tap Configure Zaptec products then tap Configure via Bluetooth at the
bottom of the screen
• Enter your PIN code. This is unique to each charging station. This will be
stated on the box and the zipped bag, or alternatively can be obtained
from the Zaptec Portal cloud service (after the charging station has been
added to the installation in the Zaptec Portal)
• Go to settings and scan for charging stations. Check that you are
connected to the correct charging station. There should be a flashing white
light on the status indicator of the charging station.
• Configure the power grid in accordance with the installation, and select the
communication method to be used.
• The charging station is online when you can see a green bar on the screen.
• This must be done for all the devices in the installation.
Troubleshooting: If the charging station does not come online, check that the
network setup is in accordance with the network requirements in the chapter
“Internet and Network Requirements”.
The portal installation must be set up identically to the electrical installation.

16
English
Verify the installation in the Zaptec Portal
Check that all the charging stations have been added to the installation in the
Zaptec Portal, as described in the chapter “Prepare for the installation in the
Zaptec Portal”, to make sure that all the charging stations are present.
Test the charging stations
• Perform an RCD test using a testing device with a Type 2 plug. The test
must be performed in accordance with the testing device’s manual.
• Carry out a test using an electric vehicle, test load or Mode 3 test
equipment.
Handover and Zaptec Portal access
totheinstallationowner
Hand over the user manual, SmartKey and final checklist to the owner.
Add the installation owner/owner group to the installation.
• Inform the owner/owner group of the jointly owned property/installation
that they must register as a user in the Zaptec Portal before they can gain
access to the installation.
• Go to Authorisations in the Zaptec Portal, Grant authorisation and add the
user(s) who are to administer the installation as owner. They will only be
visible if they have registered a user profile in the Zaptec Portal.
• Show the Zaptec Portal dashboard to the owner and give a brief
presentation of the functions.
Authorisations in the Zaptec Portal
Administrator: Gives access to settings, access control, statistics and power
consumption for the installation.
Service: This is a technical role which gives authorisation to add installations,
circuits and charging stations.
User: All authenticated users of the installation. They will only be able to see
their own power consumption.

17
English
5. Troubleshooting
Warnings/error messages are displayed in the Zaptec Portal / Zaptec App.
Problem Solution
Cannot log on to
the Zaptec Portal
Reset password by clicking on the button for forgotten password.
Cannot create new
installations in the
Zaptec Portal
New installation technicians/service partners must contact Zaptec’s technical support
at [e-mail] to obtain authorisation to create installations.
The charging
station is not online
4G
• Inadequate GSM network coverage.
• 4G not activated on the charging station.
PLC installations
• There may be an active firewall. Check the network setup on the router/modem.
• Check that the internet is working by connecting the computer directly
to the router/switch.
• The charging station must be encrypted with respect to the associated PLC module.
• Check that the PLC has been installed in accordance with the circuit diagram
andonthe same L1 and N as the charging station(s).
• Check that the network icon is flashing green.
• Check that the HomePlug icon is flashing and illuminates red.
• The power icon should illuminate green steadily.
WiFi installations
• There may be an active firewall. Check the network setup on the router/modem.
• Check that the internet is working by connecting a phone, tablet or computer to the
WiFi network.
• Unable to connect. Check that the SSID and the password for the WiFi are correct.
• If the network is not visible, you must check that the WiFi access point uses 2.4 GHz
(5 GHz is not supported), and that it uses channels between 1 and 11.
• If the network name (SSID) is hidden, you must enter the SSID and password
manually using “Other” in the network list.
• Unable to connect. Check that the SSID and the password for the WiFi are correct.
• If the network is not visible, you must check that the WiFi access point uses 2.4 GHz
(5 GHz is not supported), and that it uses channels between 1 and 11 (12 and higher
are not supported).
• If the network name (SSID) is hidden, you must enter the SSID
andpasswordmanually.
Charging does not
start
Check that the user profile has the right access to charge on this charging station.
If charging does not start or the status indicator indicates a charging error by
illuminating red steadily.

18
English
Colour Meaning
NO LIGHT
Charging station has not been activated in the Zaptec Portal, no power from the power
circuit, incorrect connection or product fault. Check the upstream circuit breaker
inthedistribution cabinet.
PURPLE Firmware updating.
GREEN Check that the charging cable has been inserted into the charging station correctly.
Check that the vehicle has been configured to start charging immediately.
BLUE Communication is taking place between the charging station and the vehicle.
Check whether the vehicle is configured to start charging immediately.
RED Flashing red light
Authentication failed – Check that the RFID tag/charging card is connected
to your user profile.
Authentication failed – Check in the Zaptec Portal that your user has access
to charge on the charging station and/or installation concerned.
Steady red light
Disconnect the charging cable. If the status indicator illuminates green, you can
connect the charging cable again. If charging does not start and the indicator
illuminates red again, there may be a charging fault on the charging cable or vehicle.
If the status indicator lamp does not turn green after the charging cable has been
disconnected, you must check the fuses as described in the chapter “Checking
thefuses in the charging station”.
If this does not help, make a note of the serial number of the charging station
and contact user support as explained in the chapter “Support and Repairs”.
The location of the serial number is shown in the illustration.
Serial number,
e.g. ZPR123456
If the charging station has been disconnected from the power grid,
it will take two to three minutes to restart.

19
English
Check the circuit breaker in the charging station
1
Remove the front cover using the
SmartKey* special tool supplied with
the charging station, and take the
front cover off.
2
Check that the circuit breakers in
the circuit breaker window have
not tripped (they should all face
upwards).
3
If any of the circuit breakers have
tripped, remove the circuit breaker
cover using the snap cover and flip
the circuit breakers up again. Fit the
circuit breaker cover as in step two
and clip the cover into place.
* If the charging station is mounted on a Zaptec Column, you must use a SmartKey Column
(supplied with the column) in order to access the charging station.
6. Storage and Maintenance
The product must be stored in a cool, dry place. The protective cover
must always be fitted when the product is not in use.
The following periodic maintenance is recommended:
• Wipe down the charging station with a damp cloth.
• Make sure there are no foreign objects in the charging connector.
• Check that the charging station has no physical external damage.
Periodic checks should be carried out on all publicly accessible installations,
in accordance with local legislation.
7. Guarantee
We guarantee that the device is free from material faults and complies with
applicable consumer protection laws and regulations in the country in which the
product was purchased or the consumer resides. Further information about your
rights under consumer legislation can be found at zaptec.com/guarantee. Your
Zaptec product comes with a five (5) year guarantee. Please find the guarantee
document at zaptec.com/guarantee
8. Support and Repairs
The installation technician/service partner is always the first line of support in the
event of problems with the installation. Zaptec strongly recommends that the
installation technician complete the dealer course for Zaptec Pro before installing
a Zaptec Pro system. If you are a Zaptec dealer, contact support as stated in your
dealership contract, or via zaptec.com.