HYDRA 2023v1 AC Wall Mounted EV Charger Instruction Manual

ZODIAC
AC wall-mounted EV charger ELECTRIC VEHICLE CHARGER
INSTALLATION AND INSTRUCTION MANUAL
ZODIAC-2023v1

SAFETY

SAFETY ANNOUNCEMENTS
Before operating the EV charger, read the instructions and precautions carefully to reduce the risk of accidents. The “Caution, Warning and Hazard” notices on the charger and in the product manual do not represent all safety concerns to be observed and are only intended to supplement the various operational safety precautions. In carrying out the company’s product and equipment operations, you must comply with relevant industry safety norms and strictly abide by these instructions to provide the appropriate equipment precautions and special safety instructions
IDENTIFICATION DESCRIPTION

| Indicates that care must be taken with the operation or condition of hazardous voltage
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| Important security information must be followed very carefully
| Indicates risk of burns from high-temperature areas or areas with high component temperatures
**| Ground protected connection point
AC**| AC electricity
| Indicates that the said action must be performed using clothing and/or personal protective equipment provided by the employer

ELECTRICAL SAFETY
HIGH VOLTAGE

| Some components of the power system operate with high voltage. Direct or indirect contact with these components through non-insulated protective material poses a fatal hazard.
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The installation of AC power supply equipment must comply with safety regulations, and personnel carrying out the installation of AC equipment must be qualified in high voltage AC-power operation.
It is strictly prohibited to wear watches, bracelets, rings or other conductive objects on your wrist or hand.
Turn off the power immediately if you find water or moisture in the unit. When operating in humid conditions, water should be strictly prevented from entering the equipment.
A “Do not operate” sign must be hung on switches and buttons that are not to be used during installation.

| Construction of high-voltage lines can cause fire or electric shock accidents.
The racking and wiring of AC cables through the area must comply with the local regulations and specifications. Only personnel qualified for high- voltage and AC operations can carry out various high-voltage operations.
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TOOLS

| Special tools must be used for all high AC voltage operations.
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THUNDERSTORMS

| High AC voltage operations during thunderstorms are strictly prohibited.
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Strong electromagnetic fields are produced in the atmosphere during thunderstorms. To avoid lightning damage to equipment and personnel, do not carry out any operations during thunderstorms.
ELECTROSTATICS

| Static electricity generated by the human body can damage electrostatic- sensitive components on boards such as large-scale integrated circuits (ICs). To prevent static damage to sensitive components, personnel must wear an anti- static bracelet when in contact with equipment (hand-held boards, circuit boards, IC chips, etc.). The antistatic bracelet must be well-grounded on the other end.
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SHORT CIRCUITS

| It is strictly prohibited to short-circuit the power supply system to the positive and negative poles or to short the non-ground pole to ground during operation. Short circuits can cause equipment to burn and pose a personal safety hazard.
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In addition, the polarity of the cables and interface terminals must be strictly checked when carrying out live work.
Power distribution operation space is limited. Before any operation, close attention must be paid to the choice of operating space.
An insulation tool must be used during operation.
When working with electricity, care must be taken to keep your hands, wrists and arms steady, to prevent accidents from a tool slipping, or from too much movement of a tool or your body.
SHARP CORNERS

| When moving equipment by hand, wear protective gloves to prevent cuts.
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POWER CABLE

| Make sure that the cable label is correct before connecting the cable.
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SIGNAL LINE

| The signal cable should be tied separately from the power cable and at least 15mm away.
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INTRODUCTION

SERIAL NUMBER DESCRIPTION

The Hydra Zodiac wall-mounted, AC Electric Vehicle Charger can be configured with Type 1 J1772, Type 2 cable (tethered) or socket (untethered 1 J1772, Type 2 cable (tethered) or socket (untethered). The system can be installed outdoors (but for safety reasons, if the water/snow level reaches the charger connector it should not be used).

APPEARANCE & DIMENSIONS

1. LED Status indicator light
2. Charging Socket (untethered models)
3. Emergency Stop and Reset Button
4. Backplate Fixing Screws x 4
5. Power Cable inlet
6. Ethernet port (option)
7. Cable Plug inlet (tethered models only)

TECHNICAL SPECIFICATIONS

400V AC (L1/L2/L3/N/PE) ±10%
Input frequency| 50Hz/60Hz
Rated power| 7kW (single-phase) / 22kW (three-phase)
Measurement accuracy| ≤±0.5%
Output voltage| Same as input voltage
Output current| 32A
DESIGN FEATURES| UI| Emergency stop button, LED indicator
Charging method| Plug and charge, APP (timed start and stop)
Charging cable| Type2 (Socket/Cable)
COMMUNICATION| Web interface| WiFi/Ethernet
OCPP| OCPP 1.6j
WORKING ENVIRONMENT| Usage| Indoor/Outdoor
Operating temperature| -20°C ~ +50°C
Operating humidity| 5% ~ 95% no frost
Elevation| <2000m
Protection level| IP65
Cooling method| Ambient air cooling
Ground detection| 30mA AC, 6mA DC

PRODUCT FEATURES
The HYDRA ZODIAC AC Charger has a modern design and user-friendly interface, designed for domestic, commercial and workplace use.

SAFETY FEATURES

• Hardware protection features:
  • Emergency stop protection
  • Overcurrent protection
  • Earth leakage protection
• Comprehensive software protection features, providing multiple protections
• IP65, EMC class B/C

SMART

• The terminal charger is connected to the Open Charge Point Protocol platform online
• Remote diagnostics, remote upgrades
• Compatible with GB/T, Type1-SAEJ1772, Type 2 and IEC61851-1/2017
• OCPP Smart charging
• Support for OCPP1.6-J (direct upgrade to 2.0 when required)

CONVENIENT

• Wireless or wired communication, flexible networking
• Open communication protocol for sweep charge, swipe charging and API services
• Several settings to end the charge
  • Time limit
  • Amount of electricity

OPTIONAL FEATURES

• Plug and Charge (optional)

SYSTEM ARCHITECTURE

ELECTRIC
Transformer – Switch – Charger – Car

INTERNAL SYSTEM COMMUNICATIONS

INSTALLATION

PROCEDURE
SAFETY INSTRUCTIONS
The operating voltage and current inside the charging system are high, and the following regulations should be observed at all times to ensure personal safety:

1. Charging systems must only be installed by personnel who have been trained in, and have sufficient knowledge of, the charging system. Always follow safety precautions and local safety regulations during installation.
2. To operate inside the charging system, make sure that the charging system is not live. The power input to the charging system must be disconnected.
3. Distribution cable wiring should be reasonable and protective to avoid accidental contact when operating power supplies.

VISUAL INSPECTION
Upon product delivery, check that the package is not damaged and that the label is complete and correct. If there is an issue, immediately inform the carrier and take photos as evidence. At the same time, immediately contact the manufacturer to discuss the issue.
Only after the goods arrive at the installation site can they be opened and the boxes opened for inspection. Start by opening the box with the packing slip, taking out the packing list and checking it against each item. Next, check the serial number of the box, the equipment packaging, the number and type of accessories and the integrity of all items.
Following the packing list, check that accessories and accompanying documents are complete (refer to the shipping list) and store the accessories and documents properly.
Carry out a visual inspection to ensure that the product is free of abnormal marks showing collisions, and of scratches, cracks, dents, rust, breakage, or peeling of paint.
Sign receipt documents, make a record of the situation, keep documents and scan them for archives, or give them to relevant parties.
ACCESSORY LIST
The packing list comes with the shipping documents.

SITE SPACE REQUIREMENTS
Adequate installation space should be reserved to ensure safe and reliable operation, ventilation and maintenance of the equipment. Installation requires 250x400mm of space

MOUNTING REQUIREMENTS
When the backplate is used to hang the charger on the wall, ensure that the variation in wall smoothness is within ±1.5mm per square meter and that the strength level of the installation position is not less than C30. Four M4 expansion screw holes are embedded in the mounting surface.
To avoid the back plate distorting when being screwed onto the wall, it is recommended that you fix each screw loosely one at a time and then tighten slowly once all screws are in place.

ELECTRICAL REQUIREMENTS
Cable type: TN-C-S/TN-S confirming the need for shielding as required by local laws or norms

• If there is a shield, both ends of the shield are connected to the PE secure ground.
• Cable diameter requirements are determined by the contractor or electrical engineer, based on power, distance and industry standards, or the following recommendations:
  • ZR-YJV-multi-core-sheath power cable.
  • The voltage level is 450/750V or higher.
• A temperature of at least 90°C should be achieved.
• PE Safety ground wire requires the same size model as the N wire, or uses the following recommended requirements:
  • When the phase line is greater than 35mm, the ground line should be no less than half of the phase line section.
  • When the phase line is greater than 16mm and less than or equal to 35mm, the ground line should be consistent with the phase section.
  • The section of the ground line must not be less than 16mm.
• The recommended power distribution input wire diameter of the charger should not be less than the following recommended values and should have a separate circuit breaker and leakage (the following table is at 25°C environment, YJV22 (armoured) cable in the soil directly applying flow as a reference, according to the actual cable material and laying method to determine the specific wire diameter).

NETWORK CONNECTIVITY REQUIREMENTS
The recommended way to connect to the network is via the WiFi module integrated within the charger. Make sure the signal strength is strong and stable at the location where the EV charge point is installed; otherwise a WiFi signal amplifier (booster) may be required.
If there is no or poor connection a standard wired internet connection (RJ45 ethernet) is an option. Wired connections must meet the following requirements:

• RJ45 Ethernet
• Network cable type: 5e class or greater, 8P plus PE, shielding wire.
• It is recommended that the line length is less than 75m. Greater than 75m length requires a customised solution.
• Minimum bandwidth required:
  • Upstream: 128 kbps
  • Downstream: 4 Mbps
• Demand connection reliability: 99.9%.
• For special configurations, please contact us.

TOOL PREPARATION
STANDARD TOOLS

CONNECT THE POWER CABLE
Note: Turn off switches and pull out all fuses before connecting electrically
CONNECT THE GROUND CABLE
The charging system uses a common grounding method, using a ground cable to connect the ground copper row of the charging cabinet with the main ground row.
CONNECT THE AC INPUT

1. The AC input cable is routed from the user’s power distribution switch and is connected to the output terminal of the user switch when power is ready to be turned on. The user distribution switch should have overcurrent, short circuit, lightning strike and other protective devices. The capacity of the power distribution switch is recommended as not less than 1.5 times the actual load capacity. Please ensure the The Zodiac has its own dedicated circuit – EV charging equipment in the UK is required by law to have its own dedicated circuit.
2. The L1-phase, L2-phase, L3-phase and N-zero cables of the AC input cable should use brown, black, grey and blue cables (standard reference below). If the cable has only one colour, the line number identification is pasted or marked with different colour insulation at both ends of the cable.
3. Cables should not have severed heads, broken heads or scratches.

PHASE LINE / ZERO STUD / IDENTIFICATION CHART

INSTALLATION INSTRUCTIONS
OPENING THE ZODIAC EV CHARGER HOUSING
The faceplate of the Zodiac EV charger is held in place with six small screws (three each side). These cannot be accessed once the EV charger has been mounted onto the wall.

Lay the Zodiac face down on a level surface taking great care not to scratch the faceplate. Use the foam sheets from the original packaging to protect it.
In addition to the power cables to the charging socket (Untethered version) there is a communications antenna wire (black) and power cable to the LED status indicator light (white/ red ribbon) attached to the back of the faceplate.

On some models there is an additional antenna wire (black) for an RFID card reader.
It is vitally important to the function of the EV charger that these wires are not disturbed.

INSIDE THE ZODIAC EV CHARGER (SOCKET ONLY MODEL)

Above shows the single-phase 7kW Hydra Zodiac with the quick-connect tail attached. When disconnecting this to attach the power cable direct to the charger the CT clamp needs to be re-installed on the live feed.
Tamper Boundary Warning Switch
This has been addd to the Hydra Zodiac 2023 model to comply with the Secure OZEV regulations which are now in force.

CONTENTS

INSIDE THE ZODIAC EV CHARGER (UNTETHERED MODEL)
The terminals on the model above (from left) are PE, L, N

A 5-terminal block is fitted to the 22kW, three-phase model, and also on some 7kW models. (see below)
Here the terminals are designated PE, N, L1, L2, L3
Always check wiring order marked on PCB

CT CLAMP ORIENTATION (WHERE FITTED)
Please make sure that the orientation of the CT clamp is correct (where fitted): The Black/Red wire exiting the CT clamp should face the direction of the board to achieve a correct reading. If the side of the CT clamp with these wires is facing away from the board it will not give accurate readings.
For the three-phase Hydra Zodiac (below right) each CT clamp needs to be attached to the correct feed and with the correct orientation (black/red wire facing the board).
(Please Note: Later models take the reading direct from the board and no separate CT clamp is used)

ACCESS PORTS UNDER THE ZODIAC CHARGER

The Hydra Zodiac has three access ports underneath, these are for:
A Power in (LEFT on all models),
B RJ45 Ethernet cable (CENTRE on some models),
C Charging Cable Out (RIGHT on tethered models only)

COMMISSIONING

POWER-ON PROCESS
Ensure that the charger is installed properly and attached securely to the wall. Check that the wires are wired correctly and the charger can be powered up.
After the Hydra Zodiac is powered up the LED indicator light on the faceplate should be BLUE, either flashing or steady and constant.
If it does not show a blue indicator light please refer to the apendix of this manual where it describes different LED indicator status lights.
CHARGING OPERATION
There are two methods to commence charging: simple Plug-and-Charge or via the smart-phone App: HYDRA HOME.
Before charging, please make sure that the charging cable is firmly inserted into the charging port of the vehicle.
If the customer intends to use the App to facilitate charging, set up charging times, record charging sessions or to allow other family members to use the chargepoint, please refer them to the HYDRA HOME APP USERGUIDE.
DO NOT pair the Zodiac charger to the app on your own phone, this will prevent the customer being able to pair it to their account. If you wish to test the Zodiac operation from the Hydra Home App please ask the customer to register an account and pair the zodiac to their own smartphone then guide them through the process.
EMERGENCY OPERATION
Refer to this section only if an exception has occurred or the charger has been mishandled.
Emergency stop: In the event of an emergency, quickly remove the transparent protective cover (if present) and press the metal/ silver Emergency Stop button to cut off the output power supply. Do not use the Emergency Stop button for normal shutdown.

FORCED UNPLUGGING AND RECOVERY
Forced unplugging of the charging outlet is prohibited during charging!
If the normal stop operation does not occur, it is recommended to press the Emergency Stop button and then manually unlock to prohibit forced pull-out of the outlet.
DOWNLOAD THE APP
For iPhones, please use App store to search “Hydra Home” to download and install the app.
For Android phones, please use Google Play to search “Hydra Home” to download and install the app.

| | Android phone| Android 5.0 and above (8.0+ recommended)
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| iPhone 6 and above| IOS 11.0 and above

REGISTER AND LOGIN
We have produced a comprehensive User Guide for the HYDRA HOME App which is accessible online. Scan the QR code found in the packaging or on download it here: www.hydraev.co.uk/support

CHECK BEFORE COMMISSIONING
BEFORE STARTING ANY COMMISSIONING OF THE ZODIAC, THE FOLLOWING CONDITIONS NEED TO BE PREPARED AND VALIDATED:

• All preparation, installation, connections, etc. have been completed.
• The Zodiac input power supply has been connected and the charger power-up capacity is already available.
• If there is no Wi-Fi signal, the zodiac needs to be connected via a wired RJ45 Ethernet cable.

POWER-ON CHECK
Once the charger is connected to AC power, check the LED light is on and pulsing BLUE to signal that is in an idle/ready state. Next configure the network connection via the APP.
CHARGING OPERATION

• Connect an electric vehicle, EV simulator or other suitable testing device. The charger must show that the electric vehicle is connected.
• Use the APP to commence charging or set up ‘Plug and Charge’ to start charging and check the Zodiac starts the normal charging process
• Check the charger’s LED light is GREEN and the module is working.

AFTER-SALES MAINTENANCE

AFTER-SALES SERVICE

• Parts and labour are covered by a three-year warranty (go to www.hydraev.co.uk/support to obtain your warranty document)
• During this period any defective part will be replaced.
• One-to-one technical engineer support is available: go to www.hydraev.co.uk/support

DISCLAIMER
This equipment must be used under normal conditions. Should the following circumstances lead to an accident or damage, we will not be held responsible.

• All human factors, damage and use in an abnormal working environment
• Failures and damage caused by improperly using the device or not following instructions.
• Damage caused by transport after delivery.
• Normal wear, breach or immersion.
• Use of parts not authorised by the manufacturer (such as aftermarket or counterfeit parts).
• Dismantling, repairing or modifying the products without the prior consent of the company.
• Damage caused by flood, fire, lightning strike, typhoons, earthquakes or abnormal voltage.
• Accidents, faults or damages outside the warranty period.

MAINTENANCE
DAILY MAINTENANCE
Regular servicing maintains the charger’s safety and condition.
REGULAR MAINTENANCE
MONTHLY

• Check the charger is still perfectly upright.
• Clean any dirt on the outer surface.
• Check for damage to the painted surface.
• Test the charging outlets and cables.
• Check the LED display status.

QUARTERLY

• Check the ground screw and ground resistance (no greater than 1Ω).
• Check the charger’s alarm light is green and the module is working.

SEMI-ANNUALLY

• Check ground bolt torque and tighten if required (pedestal mounted units)

ANNUALLY

• Arrange for a qualified electrician to check all internal components and wiring.

ON-SITE MAINTENANCE
This device is an internet of Things-type charger with pre-charge self- test, daily regular self-test, online monitoring of electrical parts and other intelligent functions.

• If working, simply perform routine maintenance, no overhaul maintenance is required.
• If not working properly, promptly contact our customer support centre or your local supplier.

REMOTE MAINTENANCE
The Hydra Zodiac can remotely connect to our cloud platform to monitor the status of the charger in real time. When connected, the platform can provide remote diagnosis, remote service and remote firmware upgrade services as required. It can also locate problems and provide solutions to help our support technicians carry out remote services. It can remotely upgrade software, solve end-user problems and carry out unattended operations.

• The system self-tests daily. If there is an issue, it will escalate it automatically.
• If there is an abnormal operation, please contact the customer service centre or local supplier promptly.
• Service engineers can query logs, update configuration and procedures, carry out remote management, diagnosis, configuration, upgrades and other remote maintenance actions.

PROCEDURES

DURING INSTALLATION, REPAIR AND REPLACEMENT OF PARTS

• Live work is strictly prohibited.
• Unauthorised dismantling is strictly prohibited.
• Follow safety procedures when operating the equipment.
• Access to the power supply line should be followed in the PE ground -> zero-line -> phase line order.
• All operations must comply strictly with relevant safety standards.

AFTER INSTALLATION, REPAIR AND REPLACEMENT OF PARTS

• Refer to the installation and maintenance requirements for validation and testing.
• Bring your own tools to restore the internal switch.

APPENDIX

LED INDICATOR STATUS IDENTIFICATION

FAULT DIAGNOSTICS

to the charger.
Check if the power cable to the device has a short circuit. If these checks are normal, please try to power off the Zodiac charger and restart. If the fault persists, please contact your EV chargepoint installer or Hydra EVC support.
Cannot lock the charging connector| The charging gun is not properly connected with the charging port of the car or the electronic lock or the charging gun is faulty.| Remove and reconnect the charging gun ensuring it is properly seated within the car and the Zodiac charger. Restart the Zodiac charger using the emergency stop button. Try a different charging cable if possible.
If the fault persists, please contact your EV chargepoint installer or Hydra EVC support.
Cannot unloc| The electronic lock of the charging gun is faulty or stuck.| Restart the Zodiac charger by pressing the emergency stop or power off to allow you to disconnect the charging gun.
If the fault is still not eliminated after reconnecting, please contact your EV chargepoint installer or Hydra EVC support.
Unusual LED indicator light status| The emergency stop button may have been pressed or the charger is faulty.| Please refer to the appendix later in this document for the description of the LED status indicator lights.
Try to power off and restart. If the red light is illuminated or flashing, please make sure that the emergency stop button is pressed first. If it is pressed, please press it again to reset. If the fault is still not rectified, please contact your EV chargepoint installer or Hydra EVC support.
For any other issues not covered above, please contact us. Go to www.hydraev.co.uk/support

RESTRICTION OF HAZARDOUS SUBSTANCES
ELEMENT IDENTIFICATION TABLES (ROHS)

Polybrominated diphenyl ethers
| PB| HG| CD| CR6+| PBB| PBDE
Cabinet, box and copper row| x| •| •| •| •| •
Charging module| x| •| •| •| •| •
Monitoring module| x| x| •| •| •| •
Distribution parts| x| •| x| •| •| •
Circuit board| x| •| •| •| •| •
Hardware| x| •| •| •| •| •
Cable| x| •| •| •| •| •
•  Indicates that this toxic or hazardous substance contained in all of the homogeneous materials for this part is below the limit requirement in SJ/T 11363-2006
x Indicates that this toxic or hazardous substance contained in at least one of the homogeneous materials used for this part is above the limit requirement in SJ/T 11363-2006
The following components or applications containing toxic and harmful substances are limited by the current level of technology, with no reliable alternative or solution:
1. Solder contains lead
2. Copper alloys contain lead
3. The contacts of the switch contain cadmium
4. The backlight tube contains mercury
Description of the environmentally friendly use period: the environmentally friendly use period of this product (marked in the product body) refers to the period of time from the date of production of the product containing toxic and harmful substances or elements that will not have a serious impact on the environment, persons and property, subject to normal conditions of use and compliance with the safety precautions of this product.
SCOPE OF APPLICATION: AC SINGLE OUTLET CHARGER

AUTHENTICATION
CERTIFICATION

HYDRA EVC Ltd
Telephone: 01268 205 121
Email:sales@hydraev.co.uk
Unit 11, Totman Close, Rayleigh, Essex SS6 7UZ
ZODIAC-2023v1

Documents / Resources

| HYDRA 2023v1 AC Wall Mounted EV Charger [pdf] Instruction Manual
2023v1 AC Wall Mounted EV Charger, 2023v1, AC Wall Mounted EV Charger, Mounted EV Charger, Charger
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References

• Hydra EVC - The Fast Charging Specialists - Hydra EVC
• Support - Hydra EVC

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