Phoenix Contact EV Charge Control Basic Manuale utente

User manual

EV Charge Control Basic

Installing and starting up the

charging controller

2021-03-24

PHOENIX CONTACT GmbH & Co. KG • Flachsmarktstraße 8 • 32825 Blomberg • Germany

phoenixcontact.com

106377_en_05

EV Charge Control Basic

Installing and starting up the charging controller

This user manual is valid for:

Designation Version Order No.

EV-CC-AC1-M3-CBC-SER-HS

EV-CC-AC1-M3-CBC-SER-PCB

EV-CC-AC1-M3-CC-SER-HS

EV-CC-AC1-M3-CC-SER-PCB

4 1622452

1622453

1622459

1622460

User manual

UM EN EV-CC-AC1-M3-C, Revision 05

Table of contents

106377_en_05 PHOENIX CONTACT 3 / 68

Table of contents

1 Properties of the charging controller ..........................................................................................5

1.1 Ordering data ........................................................................................................ 6

1.2 Technical data....................................................................................................... 6

2 Connections, indicators, configuration switches ........................................................................9

2.1 Connections .......................................................................................................... 9

2.2 Diagnostic and status indicators.......................................................................... 11

2.3 Configuration switches S1 + S2........................................................................... 12

3 For your safety .........................................................................................................................15

3.1 Safety notes ........................................................................................................ 15

3.2 Maintenance and disposal................................................................................... 16

4 Startup .....................................................................................................................................17

4.1 Dimensions.......................................................................................................... 17

4.2 Mounting the PCB (EV-CC-...-PCB only)............................................................. 18

4.3 Mounting the housing (EV-CC-...-HS only).......................................................... 18

4.4 Mounting on the DIN rail ...................................................................................... 20

4.5 Connecting the supply voltage ............................................................................ 21

4.6 Connecting the charging contactor...................................................................... 21

4.7 Locking the Infrastructure Socket Outlet (EV-CC-...-CBC-... only)....................... 22

4.8 Configuration ....................................................................................................... 22

5 Signal contacts and charging sequences .................................................................................23

5.1 Proximity Plug (PP).............................................................................................. 23

5.2 Control Pilot signal (CP) ...................................................................................... 24

5.3 Charging cable connection (case B and C) ......................................................... 25

5.4 Vehicle status (status A - F)................................................................................. 26

5.5 Typical charging sequence.................................................................................. 27

5.6 Simplified charging sequence.............................................................................. 29

5.7 Activation mode................................................................................................... 30

6 Wiring the outputs and inputs ...................................................................................................31

6.1 Outputs................................................................................................................ 31

6.2 Inputs................................................................................................................... 33

EV Charge Control Basic

4 / 68 PHOENIX CONTACT 106377_en_05

7 Connection examples ..............................................................................................................35

7.1 Charging enabled with local release.................................................................... 35

7.2 Charging enabled with local release and status indication via external LEDs...... 36

7.3 Charging enabled with local release and charging current reduction................... 37

7.4 Charging enabled with local release and locking................................................. 38

7.5 Charging enabled via Modbus............................................................................. 39

7.6 Charging current control via analog CCR signal .................................................. 40

7.7 Charging contactor monitoring ............................................................................ 42

7.8 Connection to a residual current monitoring device............................................. 44

8 Flow charts for the charging process .......................................................................................47

8.1 Charging sequence 1 .......................................................................................... 47

8.2 Charging sequence 2 .......................................................................................... 48

8.3 Charging sequence 3 .......................................................................................... 49

8.4 Charging sequence 4 .......................................................................................... 50

8.5 Charging sequence 5 .......................................................................................... 51

8.6 Charging sequence 6 .......................................................................................... 52

9 Modbus description .................................................................................................................53

9.1 Modbus register types ......................................................................................... 53

9.2 Register assignment............................................................................................ 54

9.3 Function assignment of output registers.............................................................. 63

A Appendixes...............................................................................................................................65

A 1 List of figures ....................................................................................................... 65

Properties of the charging controller

106377_en_04 PHOENIX CONTACT 5 / 68

1 Properties of the charging controller

The EV Charge Control Basic charging controller is exclusively used to control and monitor

the charging of electric vehicles on the 3-phase AC power grid in charging mode 3 accord-

ing to IEC 61851-1, AC level 2 according to SAE J1772, and mode 3 according to

GB/T 18487.1.

The charging controller is integrated in a defined charging infrastructure which is perma-

nently connected to the power grid.

The charging controller is designed to control the switching element which is used to estab-

lish the connection between the power grid and the electric vehicle. It has a communication

interface via which status data can be read and control signals can be written. The charging

controller monitors the Control Pilot and Proximity Plug signals.

The Control Pilot signal (CP) has the following functions, for example:

– Detection of the protective conductor connection

– Detection of the vehicle status: vehicle not connected, vehicle connected, vehicle

ready for charging, ventilation required, error

– Transmission of the charging controller status: ready, not ready, error

– Specification of the maximum available charging current for the vehicle via a PWM sig-

nal

The charging controller detects the inserted charging connector and the current carrying ca-

pacity of the charging connector and charging cable via the Proximity Plug signal (PP).

Resistor coding in the charging connector is used for this purpose.

The charging controller can be used to activate or deactivate the charging connector locking

in the charging station depending on the status.

As an option, the charging process can also be influenced and monitored via the existing

communication interface.

Technical features – Evaluating and controlling the Control Pilot signal

– Monitoring the connection to protective earth ground (PE)

– Evaluating the Proximity Plug signal

– Controlling the charging contactor and locking actuators

– Maximum charging current that can be configured: 16 A, 20 A, 32 A, 63 A

– RS-485 communication interface/Modbus/RTU (slave)

– Digital inputs and outputs, can be configured

– Controlling and enabling the charging controller locking in the event of a mains failure

– Temperature range: -35°C ... +70°C

– Altitude: < 2000 m

– Versions available for charging stations with an infrastructure socket outlet (connection

of case B) and vehicle connector (connection of case C)

– Available either as PCB or with housing for DIN rail mounting

EV Charge Control Basic

6 / 68 PHOENIX CONTACT 106377_en_04

1.1 Ordering data

1.2 Technical data

Charging controller

Description Type Order No. Pcs. / Pkt.

Charging controller for connection of case B and C, with

housing for DIN rail mounting

EV-CC-AC1-M3-CBC-SER-

1622452 1

Charging controller for connection of case B and C, as

PCB

EV-CC-AC1-M3-CBC-SER-

PCB

1622453 1

Charging controller for connection of case C, with housing

for DIN rail mounting

EV-CC-AC1-M3-CC-SER-

1622459 1

Charging controller for connection of case C, as PCB EV-CC-AC1-M3-CC-SER-

PCB

1622460 1

Order number 1622452 1622453 1622459 1622460

EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB

Supply

Input voltage range 100 V AC ... 240 V AC

No-load power consumption < 1 W

Frequency range 50 Hz ... 60 Hz

RS-485 interface

Protocol Modbus/RTU (slave)

Transmission speed 9.6 kbps (default)

Can be set: 9.6 kbps or 19.2 kbps

Transmission mode

data bits / parity / stop bits 8 / N / 1

Relay output C1/C2

Switching capacity, maximum 1500 VA

Switching voltage, maximum 250 V AC

Switching current, maximum 6 A

Output, locking

Voltage 12 V DC 12 V DC – –

Current, maximum 2 A 2 A – –

Adjustable switching time 600 ms (default) 600 ms (default) – –

Digital output

Properties of the charging controller

106377_en_04 PHOENIX CONTACT 7 / 68

Voltage range, supply input

12Va 5 V ... 30 V

Maximum current per output 600 mA

Maximum total current with inter-

nal supply 500 mA

Digital input

Nominal input voltage 12 V

Nominal input current < 1 mA

Input voltage range 0 V … 3 V (OFF) / 9 V … 15 V (ON)

General data

Degree of protection IP20 IP00 IP20 IP00

Overvoltage category III (IEC 60664-1)

Pollution degree 2 (IEC 60664-1)

Ambient temperature

(operation) -35°C ... +70°C

Ambient temperature

(storage) -40°C ... +85°C

Humidity

(non-condensing) 30% ... 95%, non-condensing

Altitude < 2000 m

Dimensions W x H x D 124 mm x 128 mm

x 64 mm

120 mm x 108 mm

x 20 mm

124 mm x 128 mm

x 64 mm

120 mm x 108 mm

x 20 mm

Weight 275 g 140 g 260 g 125 g

Connection data

Connection method Screw connection

Nominal cross section 2.5 mm2

Conductor cross section, solid 0.2 mm2... 2.5 mm2

Conductor cross section,

stranded 0.2 mm2... 2.5 mm2

Stranded conductor cross

section with ferrule without plas-

tic sleeve

0.25 mm2... 1.5 mm2

Stranded conductor cross

section with ferrule with plastic

sleeve

0.25 mm2... 1.5 mm2

Conductor cross section

AWG/kcmil AWG 24 ... 14

Order number 1622452 1622453 1622459 1622460

EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB

EV Charge Control Basic

8 / 68 PHOENIX CONTACT 106377_en_04

AWG according to UL/CUL AWG 30 ... 12

Conformance/approvals

CE-compliant √

Low-voltage directive 2006/95/EC

Safety test IEC 61010-1

Function test IEC 61851-1, Appendix A

Air clearances and creepage

distances IEC 61010-1

Order number 1622452 1622453 1622459 1622460

EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB

Conformance with EMC Directive 2004/108/EC and Low-Voltage Directive 2006/95/EC

Noise immunity test according to EN 61000-6-2

Protection for housing connections

Electrostatic discharge (ESD) EN 61000-4-2 Criterion B ±6 kV (contact discharge)

±8 kV (air discharge)

Electromagnetic HF field EN 61000-4-3 Criterion B 80 MHz ... 1 GHz, field strength 10 V/m, 80% AM

(1 kHz)

1 GHz ... 3 GHz, field strength 10 V/m, 80% AM

(1 kHz)

Protection for inputs and outputs, AC power connections

High frequency, asymmetrical EN 61000-4-6 Criterion A 150 kHz ... 80 MHz, 10 V, 80% AM (1 kHz)

Fast transients (burst) EN 61000-4-4 Criterion B ±2.2 kHz (peak)

5/50 ns (tr/tn)

5 kHz rep. frequency

Overvoltages EN 61000-4-5 Criterion B 1.2/50 ns (8/20) µs (tr/ th)

Up to ±1 kV, wire-to-wire

Up to ±2 kV, wire-to-ground

Voltage dip EN 61000-4-11 Criterion B

Criterion C

0% for one period

40% for 10/12 periods

70% for 25/30 periods

Voltage interruption EN 61000-4-11 Criterion C 0% for 250/350 periods

Protection for signal connections

High frequency, asymmetrical EN 61000-4-6 Criterion A 150 kHz ... 80 MHz, 10 V, 80% AM (1 kHz)

Fast transients (burst) EN 61000-4-4 Criterion B ±2.2 kHz (peak)

5/50 ns (tr/tn)

5 kHz rep. frequency

Overvoltages EN 61000-4-5 Criterion B 1.2/50 ns (8/20) µs (tr/ th)

Up to ±1 kV, wire-to-ground

Connections, indicators, configuration switches

106377_en_04 PHOENIX CONTACT 9 / 68

2 Connections, indicators, configuration switches

2.1 Connections

Figure 2-1 Connections

GND

12V

12Va

CCR

OUT

ERR

CHG

CON

LD1

LD2

L0+

L0-

Relay

R 485S

Outlet

Power

PWR

S1 S2

CON

ERR

CHR

345

Table 2-1 Connections

No. Name Meaning Description

1LLine Phase, power grid 100 V AC ... 240 V AC (L-N)

NNeutral Neutral conductor, power grid

PE Protective Earth Functional earth ground, connected to protective earth ground

2GND Ground System ground, connected to protective earth ground

12V Power Output 12 V DC, max. 500 mA

12Va Auxiliary Power Supply input of the outputs 5 V DC ... 30 V DC

EN Enable Digital input, can be configured, enable charging process

XR External Re-

lease

Digital input, can be configured,

charging station availability

Activation via S1/DIP 2, can be configured

ML Manual Lock Digital input, can be configured,

manual locking

Activation via S1/DIP 3, can be configured

CCR Charge Current

Reduction

Digital input, charging current limit Depending on the default settings by

S1/DIP 5 + 6

IN Auxiliary Input Reserved for future expansions

OUT Auxiliary Out Digital output, can be configured Default: output can be set via Modbus *

ERR Error Digital output, can be configured Default: set when errors occur

Error or status E or status F

CHG Charging Digital output, can be configured Default: set when the charging contactor is

actuated

CON Connect Digital output, can be configured Default: set when a vehicle is connected to

the charging controller

EV Charge Control Basic

10 / 68 PHOENIX CONTACT 106377_en_04

For further information on the configuration options for the digital inputs and outputs,

please refer to the “Modbus description” on page 53.

3LO- Locking Control of the locking actuator †

LO+

LD2 Lock Detection Digital input, for connecting the locking confirmation, can be configured †

LD1

PP Proximity Plug Test signal Current carrying capacity of the connected

charging connector and charging cable ac-

cording to

IEC 61851-1

†

CP Control Pilot Pilot wire signal Communication between charging station and

vehicle according to IEC 61851-1, SAE J1772

and GB/T 18487.1

4SG Signal Ground Ground signal for the RS-485 communication interface

BRS-485 Communication interface

5C2 Contactor Relay output, charging contactor Switches the mains voltage to the vehicle via an

external

charging contactor when status C or D is reached

and

the enabled inputs and registers are active.

*Not protected against overload

†Not for EV-CC-AC1-M3-CC-...

Table 2-1 Connections [...]

No. Name Meaning Description

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