ZUCCHETTI AZZURRO ZCS User manual

EV CHARGER
3PH 22KW

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EV CHARGER
3PH 22kW
User Manual

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General instructions
This manual contains important safety instructions that must be followed during installation and
maintenance of the equipment.
Please keep these instructions!
This manual must be considered an integral part of the equipment, and must be available at all
times to everyone who interacts with the equipment. The manual must always accompany the
equipment, even when it is transferred to another user or plant.
Copyright statement
Copyright of this manual belongs to Zucchetti Centro Sistemi S.p.A. No part of this manual may be
copied (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. Please check our website at http://www.zcsazzurro.com for the latest version.
Technical support
ZCS offers a support and technical consultancy service accessible by sending a request directly
from the website https://www.zcsazzurro.com/it/support.
The following toll-free number is available for the Italian territory: 800 72 74 64.

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Table of Contents
1. Preliminary safety instructions..........................................................................................................8
1.1. Safety instructions .....................................................................................................................8
1.2. Symbols and icons....................................................................................................................11
1.3. Labels.......................................................................................................................................12
2. Product features .............................................................................................................................13
2.1. Product presentation ...............................................................................................................13
2.2. Operating diagram...................................................................................................................14
3. Installation......................................................................................................................................16
3.1. Checks before installation ........................................................................................................16
3.1.1. Installation tools ......................................................................................................................18
3.2. Installation process ..................................................................................................................20
3.2.1. Installation position .................................................................................................................20
3.2.2. Movement of the charger ........................................................................................................20
3.3. Materials and cables ................................................................................................................21
4. Electrical connections .....................................................................................................................22
4.1. Connecting PGND cables (grounding).......................................................................................22
4.2. Connecting the AC power cables..............................................................................................24
4.3. External protection devices......................................................................................................26
4.4. Communication systems ..........................................................................................................26
5. Mounting ........................................................................................................................................28
5.1. Wall mounting .........................................................................................................................28
5.2. Mounting on metal support .....................................................................................................29
5.3. Locking.....................................................................................................................................30
6. Commissioning................................................................................................................................31
6.1. Preliminary safety inspection ...................................................................................................31
6.2. Starting the charging station ....................................................................................................31
7. Configuration..................................................................................................................................32
7.1. Procedure ................................................................................................................................32

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7.2. Password setting, mode of use and power limitation...............................................................33
7.3. Menu for repairs or maintenance ............................................................................................35
7.4. Configuration of RFID card (to enable charging in online and offline mode).............................36
8. Working mode ................................................................................................................................38
8.1. Online ......................................................................................................................................38
8.2. Offline......................................................................................................................................39
8.3. Plug&Play.................................................................................................................................40
9. ZVM-GATEWAY...............................................................................................................................42
9.1. Introduction ................................................................................................................................42
9.2. Product overview ........................................................................................................................42
9.3. Features ......................................................................................................................................43
9.3.1. OCCP 1.6 Protocol....................................................................................................................43
9.3.2. Management of charger unit ...................................................................................................43
9.3.3. LED indications.........................................................................................................................45
9.4. Installation...............................................................................................................................46
9.4.1. Installation tips ........................................................................................................................46
9.4.2. Installation materials ...............................................................................................................46
9.4.3. ZVM-GATEWAY positioning......................................................................................................46
9.4.4. Internet connection .................................................................................................................47
9.5. Commissioning.........................................................................................................................47
9.6. Wi-Fi Configuration..................................................................................................................48
9.7. Back-end configuration ............................................................................................................52
9.8. ZVM-GATEWAY update ............................................................................................................55
10. Operation....................................................................................................................................56
10.1. Connecting the charger to the electric vehicle .........................................................................56
10.2. Start of charging ......................................................................................................................56
10.3. End of charging ........................................................................................................................56
11. Technical datasheet.....................................................................................................................57
12. Troubleshooting and maintenance ..............................................................................................58
12.1. Troubleshooting.......................................................................................................................58

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12.2. Maintenance............................................................................................................................60
13. Dismantling and disposal.............................................................................................................61
14. Warranty .....................................................................................................................................62

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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:
3PH 22kW
Keep this manual so that it is accessible at all times.
Recipients
This manual is intended for qualified technical personnel (installers, technicians, electricians,
technical support personnel or anyone who is qualified and certified to work on an electrical
system), responsible for installing, starting up and operating the charging station.
Symbols used
This manual provides information for safe operation and uses certain symbols to ensure the safety
of personnel and materials, and for efficient use of the equipment during normal operation.
It is important to understand this information to avoid accidents and damage to property. Please
take note of the following symbols used in this manual.
Danger: indicates a hazardous situation which, if not resolved or
avoided, could result in serious personal injury or death
Danger
Warning: indicates a hazardous situation which, if not resolved or
avoided, could result in serious personal injury or death
Warning

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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 of the product
Note

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1. Preliminary safety instructions
If you have problems or questions in reading and understanding the
following information, please contact Zucchetti Centro Sistemi S.p.A.
through the appropriate channels.
Note
1.1. Safety instructions
Highlights the safety instructions to be followed during installation and use of the equipment.
Before installing and using the equipment, make sure you read and understand the instructions in
this manual and familiarise yourself with the relative safety symbols shown in this chapter.
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.
Contact the nearest authorised service centre for any repairs or maintenance. Contact your
distributor for information on the nearest authorised service centre. DO NOT carry out repairs
yourself, as this may result in injury or damage.
Qualified personnel
Ensure that the operator has the necessary skills and training to operate the equipment. Personnel
responsible for use and maintenance of the equipment must be qualified and capable of performing
the activities described, and must also have appropriate knowledge on how to correctly interpret
the contents of this manual. For safety reasons, this charging station can only be installed and
serviced by a qualified electrician with the necessary training and/or skills and knowledge.
Zucchetti Centro Sistemi S.p.A. declines all responsibility for damage to property or personal injury
caused by incorrect use of the device.
Do not attempt in any way to repair or replace components of the charging station without the
assistance of qualified personnel.
Installation requirements
Install and start the charging station according to the following instructions. Place the charging
station on suitable load-bearing supports with sufficient load capacity (such as metal walls or
columns) and make sure it is positioned vertically. Choose a suitable location for the installation of
the electrical equipment. Make sure there is sufficient space for heat dispersion and to
accommodate future maintenance. Maintain adequate ventilation and ensure that there is enough
air circulation for cooling.

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Do not place the charging station near explosive, flammable
materials, chemical vapours or potentially hazardous materials.
Danger
Figure 1 –Do not lose or damage this manual
Transport requirements
If you encounter problems with the packaging that could damage the charging station or if you find
any visible damage, immediately notify the transport company. If necessary, request assistance
from an installer or from Zucchetti Centro Sistemi S.p.A. Transport of the equipment, especially by
road, must be carried out with vehicles suitable to protect the components (in particular, electronic
components) against violent knocks, humidity, vibrations, etc.
Electrical connections
Please follow all the electrical regulations on accident prevention.
Before connecting the electrical cables, make sure to properly
disconnect the voltage on the AC connection cables, and do not
connect any charging cables for electric vehicles.
Danger

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All installation operations must be carried out by a professional
electrician, who has carefully read this manual and understands its
contents!
Warning
Before connecting the charging station to the grid, make sure that
all the necessary permits have been obtained from the local grid
operator and that all the electrical connections have been
completed by a professional electrician.
Attention
Do not remove the information label or tamper with the charging
station.
Otherwise, ZCS will not provide any warranty or assistance
Note
Operation
Do not use the product if it has any defects, cracks, scratches or leaks, but contact your dealer or
ZCS technical service.
Contact with the electrical grid or the terminal of the equipment
may cause electrocution or fire!
• Do not touch the terminal or the conductor connected to the
electrical grid.
• Follow all the instructions and safety requirements relating to grid
connection
Danger
If the charging station is not functioning properly:
• Disconnect the input and output power supply
Warning
Take special care when charging in thunderstorms or in rain
Attention

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Maintenance and repair
Keep the charging station clean and dry; if you need to clean it, use a clean dry cloth. It is very
dangerous to touch the inside of the charging station, therefore it is strictly forbidden to do so
while the system is running. NEVER clean the inside of the charging station with a wet or damp
cloth.
•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
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
1.2. Symbols and icons
Introduces the main safety symbols on the charging station. Some safety symbols are located on the
charging station. Read and understand the contents of the symbols before installation:
Be careful of high voltage
Complies with the European Standards
Ground connection point
’Smin"“’"
There is residual voltage in the inverter! Before opening the equipment,
wait five minutes to ensure that the capacitance has been completely
discharged.
Be careful of high voltage.
Be careful of high temperature.
Complies with European standards.
Ground connection point.
This indicates the allowed temperature range.

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Read this manual before installing the charging station.
Degree of protection of the equipment according to the IEC 70- 1
standard (EN 60529 June 1997).
IP54 means that it is resistant against water and rust, therefore
also suitable for outdoor operation and maintenance.
Table 1 –Symbols present on the charger
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.

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2. Product features
2.1. Product presentation
The EV CHARGER 3PH 22kW series are electric vehicle battery chargers that can communicate
with the Battery Management System (BMS) of vehicles and provide them with the power needed
for charging, thus guaranteeing the protection of the electrical system. They do not convert the
mains voltage or current but simply regulate the flow and have internal protection devices in case
of short circuit or other types of battery faults. The charging station draws the energy needed from
the photovoltaic system (if present) or from the grid, depending on availability. The figure below
shows a typical installation (the photovoltaic system inside the barred box).
Figure 3 –Example of a charging station connected to a PV system (optional) and grid
The charging stations can only be connected to grids with voltage and frequency values within the
range specified in the technical datasheet. It is also very important to know the installation
requirements in order to understand exactly which configurations to adopt and which options to
choose.
Accessories and optional components of the charging station should be chosen by a qualified
technician who is familiar with the installation conditions.
Overall dimensions: L × D × H = 452mm × 295mm × 148mm
L × D × H = 452mm × 295mm × 174.5mm (with wall support)

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Figure 4 –Front and side view of the charging station
2.2. Operating diagram
Figure 5–Operating diagram of the charging station
The charging station connects to an electric vehicle via a Type2 connector (the cable is optional).
According to the standards, the charging station is identified with Type3 (wall-box) in which the
station is responsible for any power limitations, protections of various types and start-stop
charging. No energy conversion takes place inside the charging station.

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Figure 6 - Type2 Connector
The station is equipped with a MID metering system that measures the energy supplied to the
vehicle. The possible connection with an external communication gate also allows remote control
of the station, invoicing of the energy and other functions. It is compatible with all types of cables
and power sockets in order to ensure safe charging.
It is designed according to the EN 61851-1:2011 and EN 61851-22:2002 international standards,
which makes it compatible with industry standards. It can be connected to internet via
WiFi/Ethernet/4G and then monitored via PC or app.

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3. Installation
Figure 7 - Installation procedure
•DO NOT install the charging station near flammable materials.
•DO NOT install the charging station in an area where flammable or
explosive materials are stored.
Danger
•Take into account the weight of the charging station during
transport and installation.
•Choose an appropriate mounting position and surface.
Attention
3.1. Checks before installation
Checking the outer packaging
Packaging materials and components may be damaged during transport. Therefore, it is
recommended to check the materials of the outer packaging before installing the charging station.
Check the surface of the box for external damage such as holes or tears. If any type of damage is
detected, do not open the box containing the charging station and contact the supplier and the
courier as soon as possible.
It is also recommended that you check the contents of the packaging and make sure that they
correspond to what was declared. If not, contact your dealer to have any missing parts sent to you.

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Checking the product
After removing the charging station from its packaging, check that the product is intact and
complete. If any damage is found or components are missing, contact the supplier and transport
company.
Contents of the packaging
No.
Part
Qty
1
Charging station
1
2
Screw with built-in washer
4
3
Front opening keys
2
4
RFID activation card
2
5
Expansion plug
4
6
Self-tapping screw
4

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7
Wire ferrules
4
8
Wall support
1
9
Declaration of Conformity
1
10
User Manual
1
11
Warranty
1
Table 2 –Package contents
3.1.1. Installation tools
The following tools are required for the installation of the charging station and electrical
connections; therefore, they must be prepared before installation.

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No.
Tool
Function
1
Screwdriver
To screw and unscrew
screws for the various
connections
2
Drill
To drill holes in the wall for
fixing
3
Diagonal pliers
To cut and tighten the cable
ends
4
Crimping tool
To crimp the power cables
5
Wire stripping tool
To remove the outer sheath
of the cables
6
Rubber hammer
To insert the expansion plugs
into the wall holes
7
Multi-meter
To check the voltage and
current values
8
Marker pen
To mark the wall for better
fixing precision
9
Measuring tape
To measure distances