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Summary of Contents for METREL A 1632
- Page 1 A 1632 eMobility Analyser Basic user guide Version 1.1.4...
- Page 2 Mark on your equipment certifies that this equipment meets the requirements of the EU (European Union) concerning safety and electromagnetic compatibility regulations. No part of this publication may be reproduced or utilized in any form or by any means without permission in writing from METREL.
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Page 3: Table Of Contents
..................... 22 NSPECTION OF CABLE 3 EV ..................... 23 NSPECTION OF CABLE ......................23 NSPECTION INTERVALS SETTINGS ON THE A 1632 AND MASTER INSTRUMENT ............24 A 1632 ........24 AIRING THE OBILITY NALYSER WITH THE ASTER NSTRUMENT A 1632 ............. 25... - Page 4 Figure 3.14: Levels of charging states ....................20 Figure 3.15: Charging speed ....................... 21 Figure 5.1: Pairing the A 1632 eMobility Analyser with a master instrument ........ 24 Figure 5.2: Toggeling between operating modes (Mode 1 and Mode 2) ........25...
- Page 5 Figure 6.1: Starting the EVSED test with Master Instrument ............26 Figure 6.2: 3-Basic EVSE configurations ..................... 27 Figure 6.3: Manual functional EVSE testing ..................28 Figure 6.4: Manual diagnostic testing ....................29 Figure 6.5: Semi-automated functional testing................. 30 Figure 6.6: Semi-automated diagnostic testing ................31 Figure 6.7: Electrical safety testing ....................
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Page 6: Introduction
Metrel has developed a special adapter to be able to do this, the A 1632 eMobility Analser, which covers the international standard EN 61851-1 for testing EVSE equipment and EN 60364-7-722 for testing special installations or locations –... -
Page 7: The A 1632 Emobility Analyser
2 The A 1632 eMobility Analyser The A 1632 eMobility Analyser is an adapter that can be used together with an installation tester, acting as a Master Instrument, to test Electrical Vehicle Supply Equipment (EVSE), Mode 2 and Mode 3 Electrical Vehicle (EV) charging cables and perform monitoring during charging. -
Page 8: Use Cases
2.2 Use cases The A 1632 eMobility Analyser is intended to be used in the following use cases: EVSE testing o EVSE functional testing o EVSE diagnostic testing o EVSE electrical safety testing Figure 2.2: Use case 1 – EVSE testing ... -
Page 9: Figure 2.4: Use Case 4 -Mode 3 Ev Cable Testing
Mode 3 EV cable testing o Mode 3 EV cable electrical safety testing on input and output side of A 1632 Figure 2.4: Use case 4 –Mode 3 EV cable testing Monitoring of the charging process Figure 2.5: Use case 5 – Monitoring of charging process... -
Page 10: Evse Testing
2.4 Mode 2 EV cable safety testing The A 1632 is capable of testing Mode 2 and Mode 3 EV charging cables. When testing Mode 2 EV cables, it is possible to test them as an EVSE charging station or as an appliance. When tested as an EVSE charging station, the EV cable has to be connected to a 1-phase shucko inlet or a 3- phase CEE wall inlet. -
Page 11: Standard En 61851-1
CS or PP pin for determining the maximum charging current allowed. Figure 3.1: Type 1 connector and pin layout Testing of AC charging stations with installed Type 1 connector is possible with the A 1632. An additional adapter between the Type 2 male connector and Type 1 socket is needed. -
Page 12: Type 2
3.1.2 Type 2 Facts: Described in detail in IEC/EN 61851-1 Know also as the Mennekes connector by the German manufacturer. Supports 1-phase AC charging up to 70 A or 3-phase AC charging up to 63 A. Used mostly within the European Union, since its regulation requires all public AC charging stations to be equipped with a Type 2 socket or a Type 2 connector. -
Page 13: Type 1 Ccs
Figure 3.3: Type 3 socket and connector Testing of AC charging stations with installed Type 3 is not supported with the A 1632. 3.1.4 Type 1 CCS Facts: Type 1 CCS is a DC charging system. Type 1 CCS inlet on the EV allows both AC and DC charging via a Type 1 and Type 1 CCS connectors used respectively. -
Page 14: Type 2 Ccs
(i.e. the CP pin), testing of DC charging stations with installed Type 1 CCS is not supported with the A 1632. The reason is that the CCS connection requires also high level communication which the A 1632 does not have. -
Page 15: Chademo
(i.e. the CP pin), testing of DC charging stations with installed Type 2 CCS is not supported with the A 1632. The reason is that the CCS connection requires also high level communication which the A 1632 does not have. -
Page 16: Charging Cases Explained
The CHAdeMO is a DC charging connector. Tha Japaneese have also implemented their own high level communication protocol. Due to both reasons descirbe, the DC charging stations with CHAdeMO connectors cannot be tested with the A 1632. 3.2 Charging cases explained 3.2.1 Charging Case A... -
Page 17: Charging Case C
The A 1632 eMobility Analyser allows testing AC charging stations with Case B charging. To be able to test the EVSE’s safety features, be sure to set the Proximity Pilot (PP) knob to the appropriate level in order to simulate the maximum allowed charging current. -
Page 18: Charging Mode 2
1-phase connection would actually be approx. 3,7 kW. Allowed connection cases for Mode 2 charging: B Testing of Mode 2 EV charging cables is possible with the use of the A 1632 eMobility Analyser. 3.3.3 Charging Mode 3 This is the safest way of private, semi-private and public charging. -
Page 19: Charging Mode 4
Table 5: Maximum Mode 3 charging capabilities Allowed connection cases for Mode 3 charging: B, C Testing of Mode 3 charging stations is possible with the use of the A 1632 eMobility Analyser. 3.3.4 Charging Mode 4 This mode is used for fast charging a.k.a high power charging. The typical output power is currently from 50 to 120 kW although EVSE equipment with up to 400 kW can already be seen on the market. -
Page 20: Max. Charging Current (I.e. Charging Speed)
According to the EN 61851-1 standard, the following CP states are defined: A EV not connected to EVSE. B EV connected, EVSE not charging. C EV connected, EVSE charging. D EV connected, EVSE charging,ventilaiton requred by EVSE. ... -
Page 21: Figure 3.15: Charging Speed
seen from Figure 3.15. The EV must follow the maximum allowed current limit set by the EVSE, otherwise the charging station may stop the charging process. Figure 3.15: Charging speed If the measured value if the ducty cycle is between 10 % and 85 %, then the maximum current can be measured according to the following equation: = Duty_cycle x 0,6 A If the measured value if the duty cycle is between 85 % and 96%, then the maximum current can... -
Page 22: Recommended Inspections And Inspection Intervals
4 Recommended inspections and inspection intervals This chapter refers to the eCheck directive (Richtlinie zum E-CHECK E-Mobilität, © 2017 ArGe Medien im ZVEH) and has been modified to meet the Metrel defined solution. 4.1 Inspection of EVSE • Visual inspection of EVSE •... -
Page 23: Inspection Of Mode 3 Ev Cable
Interruption PE Yes / No Interchange L-PE Yes / No External voltage U external to PE Yes / No Vehicle status Functional test Values Check status A EV not connected, EVSE not charging Yes / No Check status B EV connected, EVSE not charging Yes / No Check status C EV connected, EVSE charging (no... -
Page 24: Settings On The A 1632 And Master Instrument
5.1 Pairing the A 1632 eMobility Analyser with the Master Instrument Before performing remote diagnostic tests of an EVSE with the A 1632 eMobility Analyser being used as an remote adapter, a Master Instrument (e.g. MI 3155) and the A 1632 have to be paired. -
Page 25: Setting Thea 1632 E Mobility Analyser Operating Modes
5.2 Setting the A 1632 eMobility Analyser operating modes The A 1632 may be used in one of the two operating modes: Mode 1 (default) – Suitable for TN and TT voltage systems where N conductor is present. The PE INPUT connector is connected to the installation’s N conductor. No RCD tripping. -
Page 26: Performing Measurements
Performing measurements After pairing of the Master Instrument with the A 1632 eMobility Analyser has been done, it is possible to perform diagnostic testing with the Master Instrument being in control. To begin testing, power ON the Master Instrument and follow the procedure:... -
Page 27: Evse Charging Station Testing
6.1 EVSE charging station testing Basic EVSE testing information for further information regarding CP and PP states. Functional, error and electrical safety testing can be performed manually both on Electrical Vehicle Charging stations (EVSE) as well as on Mode 2 EV charging cables when operated as a EVSE. -
Page 28: Manual Functional And Diagnostic Evse Testing
6.1.1 Manual functional and diagnostic EVSE testing If the intention is only to test whether or not the EVSE reacts accordingly to the initiated electrical vehicle (EV) states and error situations, then the manual functional testing is sufficient. In this case the procedures described below in Figure 6.3 and Figure 6.4 should be performed. Figure 6.3: Manual functional EVSE testing... -
Page 29: Figure 6.4: Manual Diagnostic Testing
Figure 6.4: Manual diagnostic testing... -
Page 30: Semi-Automated Functional And Diagnostic Evse Testing
C Err1) and upon pressing the start button on the Master Instrument, the remote light on th eA 1632 will be turned on and the A 1632 will drive the Mode 2 cable or the EVSE to state C. The Master Instrument will wait additional 5 seconds before initiating an error on the output side of the A 1632 to make sure that the EVSE charging station reached state C. -
Page 31: Automated Electrical Safety Evse Testing
Figure 6.6: Semi-automated diagnostic testing 6.1.3 Automated electrical safety EVSE testing After diagnostic testing (functional end error) of the EVSE has been done, simply start an Auto Sequence according to the way the EVSE has been installed and follow the procedure explained in the selected Auto Sequence. -
Page 32: Figure 6.7: Electrical Safety Testing
Figure 6.7: Electrical safety testing... -
Page 33: Mode 2 Ev Cable Testing
When we wish to test Mode 2 EV cables as appliances, then first the diagnostic/error tests have to be made on the input side. These can only be made manually using the A 1632 eMobility Analyser. Semi-automatic and automatic procedures are not possible via a Master Insturment as the errors are not supported in Master Instrument’s FW. -
Page 34: Manual Functional Mode 2 Ev Cable Testing
6.2.1 Manual functional Mode 2 EV cable testing To test the complete functionality of a Mode 2 EV cable follow the procedure described below. Figure 6.9: Manual functional Mode 2 EV cable testing... -
Page 35: Manual Diagnostic Mode 2 Ev Cable Testing On The Input Side
6.2.2 Manual diagnostic Mode 2 EV cable testing on the input side To see how the Mode 2 EV cable responds to various error conditions on the input side of cable follow the procedures shown below in Figure 6.10. Figure 6.10: Manual diagnostic Mode 2 EV cable testing on the input side 6.2.3 Manual diagnostic Mode 2 EV cable testing on the output side For diagnostic testing of Mode 2 EV charging cables on the output side use one of the connection diagrams shown in Figure 6.8. -
Page 36: Manual Electrical Safety Testing Of Mode 2 Ev Cable
To be able to measure the continuity of a Mode 2 EV cable the cable itself has to have all ports opened. This is achieved with putting the A 1632 eMobility Analyser into CP state C. In order not to trip the IC-CPD (a variety of the PRCD-S+) the Master Instrument has to have the parameter Current set to ramp. -
Page 37: Insulation Measurement (R Iso)
In case other equipment is used as a Master Instrument use the appropriate implemented function. Metrel offers an additional solution for speeding up the isolation resistance testing; the A 1507 3-Phase Active Switch adapter. -
Page 38: Rcd (Ic-Cpd / Prcd S+) Measurement
Testing of the IC-CPD integrated into the Mode 2 EV cable is done on the output side of the A 1632 eMobility Analyser. To test, follow the procedure: Figure 6.13: Manual IC-CPD measurement procedure on a 1-phase Mode 2 EV cable... -
Page 39: Leakage Current Measurement
To measure leakeage of the Mode 2 EV cable simply connect it to the A 1632 eMobility Analyser and connect it to the mains. Power the A 1632 and the leakage current clamps MD 9272 ON and follow the procedure described below. -
Page 40: Mode 3 Ev Cable Testing
IC-CPD part is omitted from the tests as is any diagnostic testing via the input and output errors or the CP and PP states on the A 1632 eMobitliy Analyser. Instead the A 1632 serves only as a tool that enables us to connect measuring leads of a master instrument to both sides of the Mode 3 EV cable. -
Page 41: Insulation Measurement (R Iso)
Figure 6.16: Manual continuity measurement procedureon a 3-phase Mode 3 EV cable 6.3.1.2 Insulation measurement (R iso) Except for the cable used the procedure is the same as explained in chapter 6.2.5.2 Insulation measurement (R iso) and shown in Figure 6.12 of the same chapter. The Mode 3 EV cable should be connected as shown in Figure 6.15. -
Page 42: Testing Resistance Coding For Vehicle Coupling And Plug
6.3.1.4 Testing resistance coding for vehicle coupling and plug The resistance coding of Mode 3 and Mode 2 EV cables is used for determeining the maximum current that can flow hrough the cable while charging the EV. Different values are used for different charging speeds. -
Page 43: Onitoring With The Use Ofa 1631 Ev Monitroing Cable
6.4 Monitoring with the use of A 1631 EV Monitroing cable Figure 6.18: 3-Basic monitoring configuration 6.4.1 Monitoring of the charging process The monitoring of the CP communication and perferorming electrical safety measurements at the time of charging an EV is in some literature also refered to as the Man-in-the-Middle verification. -
Page 44: Figure 6.19: Cp Communication Monitoring During Ev Charging
Figure 6.19: CP communication monitoring during EV charging... -
Page 45: Saving Data And Reporting
Now that the data is safely stored we can connect the Master Instrument to a PC running PC SW MESM (Metrel Electrical Safety Manager). After the data has been downloaded to MESM an EVSE report can be created. Below is a sample of one such report. -
Page 46: Figure 7.3: Evse Report Example In Mesm (Part 2)
Figure 7.3: EVSE report example in MESM (part 2) For more detailed information regarding downloading of test results from the Master Instrument to PC SW MESM and EVSE report creation please refer to the MESM user manual. The MESM user manual is part of MESM SW and can be viewed via the Help menu as seen from the picture below. -
Page 47: Figure 7.5: Mesm Help
The MESM user manual will open in a PDF reader. Figure 7.5: MESM Help... -
Page 48: Abbreviations
Phase 2 conductor Phase 2 conductor opened Phase 3 conductor Phase 3 conductor opened Phase conductor opened Any phase conductor MESM Metrel Electrical Safety Manager Neutral conductor Neutral conductor opened Protective Earth Protective Earth conductor opened Proximity Pilot PRCD Portable Residual Current Device... -
Page 49: Document Versions
9 Document versions Version number Date of issue Changes Version 1.1.3 18. 02.2019 First version. Version 1.1.4 19.09.2019 Added explanation and support for EV monitoring. 10 Sources IEC 61851-1 Ed. 3 Electric vehicle conductive charging system Part 1: General requirements eCheck directive (Richtlinie zum E-CHECK E-Mobilität), ©...
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