Warning: Only Applicable to Zappi 2.1 Charge Points (Models with 'H' in their Model Number)
We have identified multiple instances of overheating around the supply terminals, attributed to the incorrect installation of certain equipment or devices. This issue poses a significant risk of damage to both the equipment and user experience.
To prevent any further incidents and ensure the safety of the equipment, we strongly advise all relevant parties to thoroughly read and adhere to the installation guidelines provided in the accompanying article. This document includes detailed instructions for the correct installation method, which will help mitigate the risk of overheating and ensure the reliable and efficient operation of the Zappi charger.
We urge all users to take this matter seriously and ensure that the installation is conducted correctly to avoid potential hazards.
Causes of Terminal Burnout
There are three primary causes of terminal burnout:
- Incorrect insertion of conductor cables into the wrong holes (cable release holes).
- Cables are being inserted too deeply into the terminal.
- Failure to use a ferrule when installing with fine or superfine stranded wire.
Example incorrect installs
Correct Method of Installation
-
Strip Length of Cable:
Strip back the cable insulation to a length of 18 mm. -
Preparation for Stranded, Flexible, Fine, or Superfine Cable:
Insert the cable into a ferrule and crimp it prior to insertion. Ensure that the ferrule barrel measures 18 mm in length. -
Cable Insertion:
Insert the cable into the respective L, N, E conductor entry holes of the terminal. No undue force is necessary; do not push further than the cable is willing to go.
Wiring Diagram
Warning: Do NOT insert any objects, including tools or cables, into the release lever hole.
If in doubt?
Refer to the yellow label located inside the Zappi, directly beneath the supply terminal, for additional guidance.
Photographic examples for reference can also be found in the Quick Install Guide included in the product packaging.
DO NOT
- Insert any tools or objects into the release lever holes: These are exclusively for releasing cables during uninstallation.
- Apply excessive force when inserting cables: Push the cable in by hand and let go. While some resistance is normal, excessive force may result in over-insertion.
- Ensure that the metal spring terminal presses only on the exposed end of the wire or the metal part of the ferrule (if used), not on the insulation or the plastic part of the ferrule.
Below are examples of correctly inserted stranded wire and ferrules. The insulated plastic around the ferrule should not be inserted beyond the extent shown in the examples.
Warning: After insertion, perform a tug test on all conductors to ensure they are securely clamped in the terminal.
Do NOT insert any cables into the release lever holes. The bottom row of circular holes is designated for conductor entry, while the top square holes are exclusively for release levers.
Warranty
Incorrect installation of Zappi Charge Points will void the warranty of the product. Our warranty policy can be reviewed here.