Zaptec Pro Charging Station User Guide

Zaptec Pro Charging Station User Guide

This installation manual contains the information necessary to safely install and control the charging station.

ZAPTEC recommends that everyone who installs our products complete 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 www.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.

Safety instructions

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. (NEK400). Repairs must be carried out by ZAPTEC or a preapproved 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 electric vehicle’s charging cable.
• 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 measuring pins, wires or anything else into the quick-release connector on the back plate. Voltage tests should be performed directly on the coupling screws or using a female coupling.
• Read the warranty at zaptec.com/privacy or contact ZAPTEC Support and request a copy

Description of the ZAPTEC Pro system

Future-proof and intelligent charging solution
Combines power electronics, built-in software which runs on the charging station and a cloud solution for configuration, monitoring and advanced algorithms.
The solution is future-proof with software updates from the cloud solution to the charging station.

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 the fuse box.

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* fuse. Charge at up to 22kW on all charging stations.

Fair use through RFID or ZAPTEC App
A built-in electricity meter gives accurate consumption readings, and a space in a shared garage or parking space can be allocated. Each user only pays for their own power consumption.

Safety in accordance with the highest standards
Type 2 port which copes with high loads over time, integrated fuses, electronic earth fault protection and temperature sensors are built into the charging station.
This means safety for both the user and the power grid.

Technical Specifications

ZAPTEC Pro is an alternating current wall or columnmounted charging station in accordance with IEC 61851-1, EVSE mode 3

Dimensions and weight
H: 392 mm W: 258 mm D: 112 mm
Weight: approx. 5 kg (including backplate)

Installation circuit
Max. 63A serial fuse on installation circuit for charging stations.

Backplate connection box
Cable cross section 2.5–10 mm2
Cable diameter 10–20mm2

Installation network, Voltages
TN, IT and TT
230VAC ±10%
400VAC ±10%

Max. current and charging output
7.36kW at 32A/1-phase
22kW at 32A/3-phase (applicable to TN networks only)
5W at standby

Fuses
Built-in 3 x 40A fuses type C

Charging point
EC 62196-2 Type 2 Female with integrated self-closing cove

Earth fault protection
Built-in type B RCD
Calibration and a self-test are carried out before the start of every charging cycle. RCD can be automatically reset by disconnecting from the charging connector.

Integrated Power Meter
MID tested and calibrated (EN.50470)

Theft protection
The front cover of the ZAPTEC Pro can only be opened using a special tool. The charging cable can be locked permanently to the charging station.

Load balancing
Together with other ZAPTEC Pro charging stations, available power in the installation will be distributed automatically between the devices and phases.

Phase balancing
The charging station will dynamically select any single phase or 3-phase in a system with other ZAPTEC Pro charging stations, depending on the available power.

Communications interface and cloud connection/network
4G LTE-M1 (subscription required) Wi-Fi 2.4 GHz, IEEE 802.11 b/g/n (channels 1-11) Powerline (PLC) – HomePlug Green PHY®, 10 Mbit/s

Identification and configuration
Bluetooth Low Energy (BLE 4.1) RFID/NFC reader – Mifare Classic, Type A PLC for vehicle interface for future services as defined by ISO15118

Standards and approvals
CE compliance in accordance with the Radio Equipment Directive
2014/53/EU and ROHS Directive 2011/65/EU, and compliance with IEC 61851-1 (TUV SÜD) and IEC 61851-22

Temperature range
–30°C to +50°C

Degree of protection
IP54, indoor and outdoor use
IK10 impact protection
UL94 5VB flammability rating
UV resistant

Electrical protection
Protection class II (4kV AC and
6kV impulse, insulation)
Overvoltage category III (4kV)

Integration services
Third-party integration alternatives
(API, Webhooks)
OCPP 1.6J
Message subscription

*32A is available but may be restricted by the condition of the vehicle’s battery and temperature increases at the charging station.

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 support@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.

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 in the fuse box
• 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. It can therefore be an advantage not to operate on full load.

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.

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.

ZAPTEC Pro

Tool which is required for installation

Location of the charging station/back plate

Installing and connecting the back plate

If the wall structure requires plugs/drilling, you must ensure that dust and dirt do not get into the junction box

Undo four screws and open the cover to access the junction box.

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.

Find the cable
The recommended cable type is a round cable (PFXP, Powerflex and PFSP), Ø 10–20 mm.
Fit the sealing cone onto the cable before you connect the cables to the junction box

Wiring
To limit the risk of leaks in outdoor installations, we recommend 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).

Connect the cables
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 that four- core cable be used in case a transformer is installed in order to provide better protection 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.

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 is used, as shown under or on the label on the back plate.

Test the connections

Test the connections in accordance with your chosen configuration.

You must not mix up the phases on the charging stations in the installation. If the phases do become mixed up, the phase balancing will not work and the fuses may trip.

Sealing cones
Place the sealing cone over the cable entry in order to seal it properly. First seal the unused cable entry using the sealing cone supplied.
The sealing cone 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.

Screw on the junction box cover
Attach strain reliefs to both cables and the sealing cone before placing the cover on the junction box and screwing in the four screws.

Use the correct sealing cone for the cable. Check the cable dimension and select an appropriate sealing cone. Small sealing cone – cable dimension 10-16. Large sealing cone – cable dimension 16-21.

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.

Do not insert measuring pins, wires or anything else into the quick-release connector on the back plate. Voltage tests should be performed directly on the coupling screws or using a female coupling.

Protect the connections
Apply the adhesive sticker to protect the connections.

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 measuring pins, wires or anything else into the quick release connector on the back plate. Voltage tests should be performed directly on the coupling screws or using a female coupling.

Install the charging station

Remove the adhesive sticker
Remove the adhesive sticker which protects the contact on the junction box, if applicable.

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.

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.

Tighten the nuts
Tighten the charging station using the four supplied nuts.

Position the charging station on the back plate
Position the charging station on the back plate and check that it makes full contact with the back plate. There should be no gap between the charging station and the back plate.

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.

Switch on the power supply to the installation

• Check that the status indicator illuminates green, 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

• Download the ZAPTEC App from the App Store / Google Play. Register as a user and log in.
• Stand close to the charging station you wish to configure.
• 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. If 4G LTE-M is used, the charging station will automatically select the 4G setting as the default.
• 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.

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.

Troubleshooting

Warnings/error messages are displayed in the ZAPTEC Portal / ZAPTEC App.

for forgotten password.
Cannot create new installations in the ZAPTEC Portal| New installation technicians/service partners must contact ZAPTEC’s technical support at support@zaptec.com to obtain authorisation to create installations.
Charging station is not online, 4G installation| •    Go into the ZAPTEC App. Check the 4G coverage indicator via the charging station settings.

•    Make sure that the charging station is not covered by anything that may prevent it receiving a signal.

•    Test the coverage at the installation site using your own mobile. A mobile with a Telenor SIM has to be used for accurate measurement.

•    Alter the location of the charging station if possible, placing it in a position with better coverage.

The charging station is not online 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.

The charging station is not online 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.

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.

No power being supplied to charging station| •    Follow the instructions in the section ‘Checking the Fuses in the Charging Station’

•    Check the main fuse in the installation

power from the power circuit, incorrect connection or product fault. Check the serial protection in the distribution cabinet.
| Not updated during charging.
| •    Check that the charging cable has been inserted into the charging station correctly.

•    Check that the vehicle has been configured to start charging immediately.

| •    Communication is taking place between the charging station and the vehicle.

•    Check whether the vehicle is configured to start charging immediately.

| 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”.

•    Authentication failed – Check that the RFID tag/charging card is connected to your user profile.

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 andc Repairs”.
The location of the serial number is shown in the illustration.

If the charging station has been disconnected from the power grid, it will take two to three minutes to start up again.

Check the fuses 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 fuses in the fuse window have not tripped (they should all face upwards).
3. If any of the fuses have tripped, remove the fuse cover using the snap cover and flip the fuses up again. Fit the fuse 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.

Storage and Maintenance

The product must be stored in a dry place with a stable temperature.
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.

In accordance with Norwegian law, annual periodic checks must be carried out on all publicly accessible installations by qualified personnel. (Ref. NEK400)

Warranty

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/privacy

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. In the event of any problems, see the chapter on troubleshooting before contacting us via zaptec.com/support.

References

• Smarte elbilladere for hjemmelading, borettslag og sameier - Zaptec AS
• Smarte elbilladere for hjemmelading, borettslag og sameier - Zaptec AS
• Personvernerklæring - Zaptec
• Support - Zaptec
• Zaptec

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