Sonel EVSE-01 Adapter For Testing Vehicle Charging Stations User Manual

Sonel EVSE-01 Adapter For Testing Vehicle Charging Stations

overview

Safety

EVSE-01 adapter is designed for measurements on charging stations for electric vehicles. It is de-signed to test the operational safety and the accuracy of the charging stations used for charging in mode 3 according to EN-61851-1 with sockets compliant to IEC 62196 Type 2. In order to provide conditions for correct operation, the following recommendations must be observed:

• Before you proceed to operate the adapter, acquaint yourself thoroughly with this manual and observe the safety regulations and specifications provided by the producer.
• ny application that differs from those specified in this manual may result in damage to the device and constitute a source of danger for the user.
• EVSE-01 should be operated only by suitably qualified persons having the necessary permissions to carry out measurements on electrical systems. Operating the Adapter by unauthorised personnel may result in damage to the device and constitute a source of danger for the user.
• It is unacceptable that the user blocks the R button permanently in the position for RISO measurement. This will inactivate voltage controls, preventing voltage to be signalled. It is unacceptable, as in this state the device cannot be used.
• The measuring voltage during the RISO measurement must not exceed 550 V.
• Using this manual does not exclude the need to comply with occupational health and safety regulations and with other relevant fire regulations required during the performance of a particular type of work.
• The adapter must not be used for networks and devices in areas with special conditions, e.g. fire-risk and explosive-risk areas.
• It is unacceptable to operate the device when:
  • it is damaged and completely or partially out of order,
  • its cords and cables have damaged insulation,
  • it was stored for an excessive period of time in disadvantageous conditions (e.g. excessive hu- midity) If the meter has been transferred from a cool to a warm environment with a high level of relative humidity, do not start measurements until the meter is warmed up to the ambient temperature (approximately 30 minutes).
• Repairs may be performed only by an authorised service point.

WARNING
Before each use, thoroughly inspect the insulation of the device, checking its wires for any damage (e.g. cracks, cuts, changes in structure or color). In case of discovering any faults, do not use the device and contact the service center. 

Safety symbols

• Attention, Danger – see the user manual.
• Device protected by reinforced insulation.

Introduction

EVSE-01 adapter allows the user to conduct electrical measurements on charging stations of electric vehicles: AC voltage station with a connector of type 2 equipped with sockets or a fixed charging cable.
In combination with MPI meters, the user may perform a wide range of tests. The adapter simulates the load acting on the cable connected to the charger and the status of the charger in relation to the vehicle. The adapter is compatible with the following devices:

• MPI-540-PV / MPI-540 / MPI-535,
• MPI-530-IT / MPI-530,
• MPI-525, MPI-520, MPI-506, MPI-502.

CAUTION!

• The adapters is designed for measurements performed with MPI meters. It is not recommended for using in other applications.
• The range of available measurements depends on the meter. See also functional comparison of MPI meters at the end of this manual.

Quick start

• Connect the adapter to the meter.
• Set the adapter at: PP = 63 A, CP = A.
• Connect the adapter to the charger (sec. 6).
• Enter the simulation settings (rsec. 5) and start individual measurements.
• Perform measurements for all required com-binations of settings.CP = C or D – with these settings, you can measure the fault loop impedance and  test residual current circuit breakers. CP = B – with these settings, you can meas- ure the insulation resistance. CP = E – this setting is used to simulate an  error.
• To disconnect the adapter from the live charger, set CP = A, and – if necessary – PP = NC.

Settings

The chargers for electric vehicles have types of lines: communication and power supply. The charging current flows through the power supply lines. The communication lines (PP, CP) transfer in-formation on the status of the receiver, resulting in the change of charger internal settings.

Fig. 4.1. Plug IEC 62196, Type 2. PP, CP – communication between the charger and receiver L1, L2, L3, N, PE – wires of the 3-phase line

PP line informs the charger about connect-ing/disconnecting the power supply cable to the receiver – if the cable is connected the indicates its rated current. CP line sends information about the current state of the receiver: connected, charging etc. EVSE-01 provides a simulation of situations when the charged object:

• is connected to the charging source via a ca-ble with a pre-set maximum current PP
• and the charging cycle is in a mode set on CP line. PP and CP settings are selected by using suitable knobs.

PP knob simulates the charging cable:

• NC – the cable is not connected,
• 13 … 63 A – the cable is plugged and has the rated current set.

CP knob simulates the vehicle-charger relation:

• position A – no connection,
• position B – connected, no charging,
• position C – charging (station without ventilation)
• position D – charging (station with ventilation)
• position E – error: CP short-circuit with EP.

Due to the many types of electric chargers, the selection of correct settings of EVSE-01 requires from the measuring person the knowledge of the tested object and pa-rameters of measurements to be performed.

Measurements

Testing of a charging station involves the RISO measurement of its insulation resistance, ZS fault loop impedance and RCD protection at different simulated conditions of the receiver.

Automatic measurements

• Connect the control plug to the meter. Find the list of charger tests in section Automatic measurements of the meter. Select the test required for your meas-urements.
• Enter the settings required during the tests.
  • For test ZL-N, ZL-L, ZL-PE[RCD]:
  • protection of phases L1, L2, L3 supplying the charger,
  • method for calculating short-circuit current Ik,
  •  RCD type.
• For RCD test:
  • rated current IΔn,
  • testing mode
  • protection type
  • test voltage UL,
  • currents to be measured,
  • phases taken into account in the
• For RISO tests:
  • test voltage,
  • measurement time,
  • bottom limit.
• Save the settings using icon Description of function icons collapsing setting fields expanding setting fields

Set the adapter at:

• PP = 63 A,
• CP = A.
•  Connect EVSE-01 to the charger and supply it with power. Press START. The automatic measure-ment sequence will start. Observe the messages on the screen and follow the prompts. The procedure consists of some or all of the following steps:
• Visual test – results from the response of the charger to different PP and CP states
• ZS – results from parameters of pow-ers supply network. Set CP = C or D,
• RCD – results from the safety device of the charger. Set CP = C or D,
• RISO – results from the basic insulation of the charger. Set CP = B.
• After completion of the measurement, a summary is displayed. The results can be saved in memory by using icon .
• Before and during RISO measurement, it is rec-ommended to press and hold the ‘R’ button. It eliminates the effect of voltage controls on the result. ►
• During the measurement of the insulation re-sistance RISO, the measuring voltage must not exceed 550 V.
• All measurements (in particular RISO!) should be carried out taking into account the documen-tation of the tested charger.

Manual measurements

• Activate the desired measuring function in the meter and enter the settings re-quired during the test.
• Connect EVSE-01 to the meter.
• f you test 3-phase chargers, use banana-socket cables
• If you test 1-phase charger, use banana-socket cables or WS adapter.

If you use the WS adapter for testing a 3-phase charger, you will be able to measure only L1 phase.

Set the adapter at:

• PP = 63A,

• CP = A.

• Connect EVSE-01 to the charger and supply it with power.

• Perform measurements for all required combinations of settings.

• Visual test – results from the response of the charger to different PP and CP states

• ZS – results from parameters of powers supply network. Set CP = C or D,

• RCD – results from the safety device of the charger.Set CP = C or D,

• RISO – results from the basic insulation of the charger. Set CP = B.

• If you test ZS, you need to measure
  L1-N, L2-N, L3-N or

• L1-PE, PE-L2, L3-PE.
  If you test RCD, you need to measure L1-PE, L2-PE, L3-PE. If you test RISO, you need to measure:  L1-PE, L2-PE, L3-PE, N-PE or

• L1+L2+L3+N-PE.
  Enter settings to EVSE-01 and start the measurement.

• Before and during RISO measurement, it is rec-ommended to press and hold the ‘R’ button. It eliminates the effect of voltage controls on the result. ►

• uring the measurement of the insulation re-sistance RISO, the measuring voltage must not exceed 550 V.

• All measurements (in particular RISO!) should be carried out taking into account the documen-tation of the tested charger.

• Not all models of the MPI meters provide the paremeter measurements of RCDs type EV.

Control signal CP
Connect the oscilloscope to the CP socket, in order to obtain information about the Pulse-Width Modulation (PWM) of the control signal. The signal has a frequency of 1 kHz. Signal duty cycle indi-cates the status of the charging station or the maximum current that the station can supply. The cur-rent value can be determined based on the following table, contained in EN 61851-1 standard.

NOTE!

• Test CP signal in relation to the PE line.
• We recommend using a battery-powered portable oscilloscopes with isolated input and differential probes that ensure galvanic isolation of the oscilloscope.
• f the ground wire of the oscilloscope is not isolated from its casing, then before connecting the oscilloscope, make sure that the PE line of the charging station is free from dangerous voltage!

Cleaning and maintenance

NOTE!

Use only the maintenance methods specified by the manufacturer in this manual. The casing of the meter may be cleaned with a soft, damp cloth using all- purpose detergents. Do not use any solvents or cleaning agents which might damage the casing (powders, pastes, etc.). Clean the probe with water and dry it. The test leads should be cleaned with water and detergents, and then dried. The electronic system of the meter does not require maintenance.

Storage

In the case of storage of the device, the following recommendations must be observed:

• disconnect all the test leads from the meter,
• clean the meter and all its accessories thoroughly,
• wind the test leads.

 Dismantling and utilisation

Worn-out electric and electronic equipment should be gathered selectively, i.e. it must not be placed with waste of another kind. Worn-out electronic equipment should be sent to a collection point in accordance with the law of waste electrical and electronic equipment. Before the equipment is sent to a collection point, do not dismantle any elements. Observe the local regulations concerning disposal of packages and used batteries/rechargeable batteries.

Basic data

Other technical data

• type of insulation according to EN 61010-1 ………………………………………………………………… double

• • measurement category according to EN 61010-1 …………………………………………….. CAT II 300 V

• ngress protection according to EN 60529 …………………………………………………………………… IP40

• pollution degree ……………………………………………………………………………………………………………. 2

•  input voltage ……………………………………………………………………………………………. 400 V (3-phase)

• frequency ……………………………………………………………………………………………………………….. 50 Hz

•  simulation of charging cable PP ……………………………………….. open circuit, 13 A, 20 A, 32 A, 63 A

• vehicle connection simulation CP …… state A (vehicle not connected)
  …………………………………………………. state B (vehicle connected, not charging)
  …………………………………………………. state C (vehicle connected, charging without ventilation)
  …………………………………………………. state D (vehicle connected, charging with ventilation)
  ………………………………………………… state E (error – CP short to PE)

• socket types ………………………………… measuring sockets: L1, L2, L3, N, PE
  …………………………………………………. 1-phase socket
  …………………………………………………. CP signal socket – PWM communication

• test lead length

  • EVSE ……………………………………………………………………………………………………………………. 1 m
  • MPI ……………………………………………………………………………………………………………………. 0.5 m

• operating temperature ……………………………………………………………………………………….. -5…+45°C

• storage temperature………………………………………………………………………………………… -20…+60°C

• dimensions …………………………………………………………………………………………. 220 x 100 x 60 mm

• eight …………………………………………………………………………………………………………………… 1.4 kg

• the product meets EMC requirements acc. to the following standards … EN 61326-1,EN 61326-2-2

Standards Safety

• EN 61010-1
• EN 61010-2-030
• EN 61010-031

Functionality

• EN 61851-1

Manufacturer

The manufacturer of the device and provider of guarantee and post-guarantee service:
SONEL S.A.
Wokulskiego 1158-100 Świdnica Poland tel. +48 74 858 38 60 fax +48 74 858 38 09  E-mail:export@sonel.pl Webpage:www.sonel.pl
NOTE!
Service repairs must be performed only by the manufacturer

FUNCTIONAL COMPARISON OF MPI METERS

References

• Sonel S.A.
• Sonel S.A.

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