Proper installation of a zappi charger is essential for ensuring safe and efficient operation. Incorrect installation can lead to overheating around the supply terminals, which may affect performance and longevity.
This guide provides helpful tips and best practices for wiring zappi charge points, especially when using push-fit connectors. By following these instructions, you can avoid common pitfalls and ensure a secure connection.
Causes of Terminal Burnout
To help prevent overheating and ensure a reliable installation, be mindful of these common mistakes:
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Incorrect insertion of conductor cables – Cables must be inserted into the correct entry holes, not the cable release holes.
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Excessive cable insertion depth – Pushing cables too deeply into the terminal can compromise the connection.
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Failure to use a ferrule for fine or superfine stranded wire – Unprotected stranded wire may not make a secure connection, leading to overheating.
Below are examples of incorrect installations:
Correct Method of Installation
To ensure a secure and compliant installation, follow these steps:
1. Strip Length of Cable
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Strip back the cable insulation to 18 mm.
2. Preparation for Stranded, Flexible, Fine, or Superfine Cable
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Insert the stripped cable into a ferrule and crimp it securely before insertion.
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The ferrule barrel should be 18 mm in length.
3. Cable Insertion
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Insert the prepared cable into the respective L, N, E conductor entry holes of the terminal.
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Apply only light pressure; do not force the cable beyond its natural stopping point.
Wiring Diagram
Important Warnings
- Do not insert any tools or objects into the release lever holes: These are exclusively for releasing cables during uninstallation.
- Do not 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.
Additional Guidance
If in doubt, refer to the yellow label inside the Zappi, located directly beneath the supply terminal, for further guidance. If you are still unsure, speak to us on 0333 300 1303
Warranty Information
Incorrect installation of Zappi charge points will void the warranty. Please review our full warranty policy here.