Bender RCMB101 User manual

Power in electrical safety
User Manual
RCMB101
CCID-20
AC/DC Ground Fault Current Module
for Electric Vehicle Charging Stations
Software version D359 V2
NAE1045320/11.2011

©Bender Inc.
All rights reserved.
Reprinting only with permission
of the publisher.
Subject to change!
Bender Inc.
USA:
700 Fox Chase
Coatesville, PA 19320
Toll Free: 1-800-356-4266
Phone: [phone]
Fax: [phone]
Canada:
5 Edvac Drive, Unit 14
Brampton, ON L6S 5P3
Toll Free: 800-243-2438
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: http://www.bender.org

3
Table of Contents
NAE1045320/09.2011
1. Safety Instructions .................................................................................................... 5
2. Function ....................................................................................................................7
2.1 Features ....................................................................................................................................... 7
2.2 Description ................................................................................................................................. 7
2.3 Function ...................................................................................................................................... 7
2.3.1 Self test after connection to the supply voltage .......................................................... 7
2.3.2 Cyclical self test ......................................................................................................................... 8
2.4 Analog voltage output X1 .................................................................................................... 8
2.5 Switching output X12 ............................................................................................................. 8
2.6 Control input X10 ..................................................................................................................... 9
2.6.1 Reset function ........................................................................................................................... 9
2.6.2 Reset and subsequent calibration of the RCMB101 ................................................. 10
2.6.3 Measuring sequence without charging electronics reset ...................................... 12
2.6.4 Verifying proper functionality of and testing X12 .................................................... 13
2.7 Starting sequence ................................................................................................................. 14
2.8 Values outside the permissible measuring range ..................................................... 16
2.9 Measuring range and switching times .......................................................................... 17
2.9.1 Measuring range ................................................................................................................... 17
2.9.2 Switching times without a contactor ............................................................................ 17
2.10 Fault detection and resulting reactions ........................................................................ 18
3. Installation and connection ............................................................................... 19
3.1 Installation ............................................................................................................................... 19
3.2 Terminal assignment ........................................................................................................... 19
3.2.1 Conductor routing through current transformer ...................................................... 20
3.3 Application examples .......................................................................................................... 20
3.3.1 Contactor is controlled by charger electronics and switching output signal . 20
3.3.2 Contactor is controlled by charger electronics .......................................................... 20

Table of Contents
4NAE1045320/09.2011
4. Technical data ....................................................................................................... 22
4.1 Data in tabular form .............................................................................................................. 22
4.2 Ordering information ........................................................................................................... 23
4.3 Approvals / Certifications ...................................................................................................23
4.4 Dimension diagrams ............................................................................................................ 24

5
NAE1045320 / 11.2011
1. Safety Instructions
Hazard of Electric Shock, Burn, or Explosion
Only qualified maintenance personnel shall operate or service this equipment. These instructions
should not be viewed as sufficient for those who are not otherwise qualified to operate or service this
equipment. This document is intended to provide accurate information only. No responsibility is as-
sumed by BENDER for any consequences arising from use of this document.
Turn OFF all sources of electrical power before performing any inspections, tests, or service on this
equipment. Assume all circuits are live until they have been properly de-energized, tested, ground-
ed, and tagged. Failure to observe these precautions will result in equipment damage, severe per-
sonal injury, or death.
Proper operation of this equipment depends on proper installation. Observe all relevant regulations,
code requirements, and standards when working on electrical installations. Neglecting fundamental
installation techniques will result in equipment damage, severe personal injury, or death.
Do not make any modifications to the equipment. Failure to observe this precaution will result in
equipment damage or personal injury.
Only use manufacturer’s and manufacturer recommended accessories with this equipment. Failure
to do so may damage the equipment beyond repair.
The RCMB101 is designed in compliance with the requirements described in UL 2231-2, "Standard
for personnel protection systems for electric vehicle (EV) supply circuits: Particular requirements for
protection devices for use in charging systems."
DANGER

Safety Instructions
6NAE1045320 / 11.2011

7
NAE1045320 / 11.2011
2. Function
2.1 Features
For use in level 1 and 2 AC electric vehicle charging systems
Detects both AC (0...500 Hz) and DC ground faults
Internal measuring current transformer with test winding and screening for electrical interfer-
ence field reduction, inside diameter 15 mm
Measuring range 0...20 mA, with analog voltage output
Switching signal at the output according to the requirements of UL 2231-2, type CCID20
Simple mounting of the module by snap-in locking mechanism at the current transformer
Monitoring of the connection to the measuring current transformer
Reset via control input X10
2.2 Description
The RCMB101 is a ground fault current module (CCID20) for monitoring AC/DC ground faults in elec-
tric vehicle charging stations. The CCID20 shall be mounted into the charging station as an open-
type circuit board. The electrical connection is made with circuit board plug connectors.
The AC/DC sensitive ground fault current module RCMB101 (alternate term CCID20) is suitable for
monitoring in electric vehicle charging stations where direct and/or alternating fault currents are
likely to occur with a value that is constantly greater than zero. This also applies to the detection of
leakage currents. The CCID20 is to be mounted into the charging stations as an open-type circuit
board. The electrical connection is established by means of circuit board plug connectors.
2.3 Function
The module detects the zero sequence current caused by leakage and fault currents in the conduc-
tors passed through the built-in current transformer. The module measures both AC and DC cur-
rents. The final value is calculated as an RMS value. A signal in proportion to the RMS value is made
available across the output X1. A second output marked X12 provides a switching signal when val-
ues are outside the permissible measuring range or in case of high or soaring ground fault currents.
2.3.1 Self test after connection to the supply voltage
Once the supply voltage has been switched on, the module carries out a two-stage self-test. In a first
sequence, a current flow of 11mA, 400Hz is applied to the test winding for one second. Then a direct
current of 22mA is applied, also for one second.
The resulting measured value of typical 1.2V of the first 11 mA test phase is available at the analog
output X1. The digital output X12 does not switch.
The 22 mA test phase causes the digital output X12 to switch after max. 800ms and makes an analog
output voltage of 4.85V available at X1.
The automatic start of calibration also causes the digital output X12 to switch.

Function
8NAE1045320 / 11.2011
2.3.2 Cyclical self test
Before each charging cycle, a reset with subsequent calibration has to be activated by the charging
control electronics via the input X10. This requirement can only be met when sufficient supply volt-
age +Us/- Us is available.
The ensuing sequence of measurements is described in "chapter 2.6.2". The automatic start of cali-
bration also causes the digital output X12 to switch. The cyclical self test is used to check the meas-
uring function of the device. This is a measure to ensure that the protective function is guaranteed.
2.4 Analog voltage output X1
The currently measured fault current is available at X1 as a proportional output voltage.
Output voltages < 150 mV or > 4.85 V not only signal a short-circuit or an interruption, but also a pos-
sible fault of the residual current monitoring module.
When a fault is recognised by the monitoring module, output X12 will simultaneously be switched
to the high-impedance state.
For details about fault detection, refer to page 17.
Values outside the measuring range >20 mA are also signalled via the switching output X12. In ad-
dition the analog output signal is provided at X1 for approx. 1.2 s and can be evaluated by the charg-
ers control electronics.
2.5 Switching output X12
Values outside the measuring range, a fault current of I20 mA or a fault detected by the monitor-
ing module are signaled by the Open Collector output X12. The switching output is in a high imped-
ance state.
Hysteresis: Only when the measured value of the residual current falls back below 10 mA, the tran-
sistor will open and the switching output X12 will be in the low-impedance state after 1.2 s.
In order to check the proper operation of the Open Collector output X12, a functional test according
to "chapter 2.6.2" can be initiated via the control input X10.
X12

Function
9
NAE1045320 / 11.2011
2.6 Control input X10
2.6.1 Reset function
A RESET of the RCMB101 can be carried out at any time via the control input X10.
NOTE: The ground fault current measurement is interrupted during this time.
For activating the RESET function, a LOW level is to be applied across the control input X10 for at least
T1 > 530 ms.
The ground fault current measurement remains active during the period T1. The ground fault cur-
rent measured at the time t2 remains stored until the residual current measurement is restarted after
applying a HIGH level at X10 for the period T3 > 5 ms.
X10
Enabling for measuring operation
Reset: End of residual current measurement
Currently measured value remains stored
T1
> 0,53 s
X12
X1
T3
> 5 ms
~ ~~
~~
~
Start of residual current measurement
Residual current
measurement inactive
HIGH
LOW
t2

Function
10 NAE1045320 / 11.2011
2.6.2 Reset and subsequent calibration of the RCMB101
X10
Switching on the test current in the test winding.
Reset: End of residual current measurement. Currently measured residual current remains stored.
T1
> 0,53 s
X10=HIGH for 50 μs...100 μs Reset and calibration
T2
50...100 μs
X12
X1
~
~
T4
4,5 s
T3
10...11 ms
~
~~
~
~
~~ ~~ ~
~
~
Begin of calibration process
End of calibration process. Start of residual current measurement.
~
~
HIGH LOW LOW
HIGH
t2
~
~
T5
0,1 s
T6
0,15 s
T7
0,85 s
T9
> 5 ms
Measuring time for a change of the residual current.
End of test current measurement and switching off the test current. Enabling for residual current measurement. Start of residual current measurement.
Begin of test current that causes a trip
T8
1 s
Tripped in less than 700ms: X12=high, X1 = 4,85V

Function
11
NAE1045320 / 11.2011
The signaling sequence at the control input X10, illustrated in the preceding diagram, results in a RE-
SET and subsequent recalibration.
For activating the RESET function, a LOW level is to be applied at the control input X10
for at least T1 = 530 ms. The ground fault current measurement remains active during the time T1.
After T1 has elapsed, the ground fault current, which in normal condition drops to 0 mA during the
period T1, is stored by the RCMB101 at time t2.
A calibration is carried out when T1 has elapsed and a HIGH level is applied at X10 for the time T2 =
50...100 μs (typically 75μs). If this occurs, the calibration will start within T3 = 10...11 ms. For this pur-
pose, the Open Collector switching output must be in the high impedance state so that a HIGH level
is applied at X12 when a pull-up resistor is connected (switching transistor blocked). The calibration
procedure approximately takes T4 = 4.5 s and is completed when the voltage at X12 drops to LOW
(switching transistor active). The test winding is then supplied with current for 2s. The resulting
measured value is output at X1 and the corresponding switching state is applied to X12.
Once the calibration procedure is completed (X12 to LOW), calibration can be repeated as frequently
as desired by applying a HIGH level at X10 for T2 = 50...100 μs.
The RCMB101 starts the ground fault current measurement when a HIGH level is applied at X10 for
at least T5 = 5 ms.
The ground fault current measured at the time t2 remains stored until the ground fault current meas-
urement is restarted after applying a HIGH level at X10 for at least T3 = 5 ms. From the time T1 has
elapsed until the time ground fault current measurement is restarted (when T5 has elapsed), ground
fault current measurement is inactive.
A calibration includes zero point measurement and testing of the permissible voltage supply.
Before and after zero point measurement, the supply voltage is checked. If the supply voltage is out-
side the tolerance, calibration will be repeated continuously. Refer to "chapter 2.7" for more informa-
tion.
If a ground fault current still in existance will result in an incorrect calibration. Once calibration is
completed, the test winding is supplied with current for 2 s and the resulting measured value is out-
put at X1 and the corresponding switching state is applied to X12.

Function
12 NAE1045320 / 11.2011
2.6.3 Measuring sequence without charging electronics reset
If a LOW level is applied across the control input X10 of the residual current monitoring module for
T < 530 ms, no RESET will be carried out. The outputs X1 and X12 will remain unaffected. The residual
current measurement will stay active.
When the condition is met that a LOW level is applied at the control input X10 for at least T1 = 530
ms, disturbing pulses will not cause a RESET of the residual current monitoring module.
X10
T1 = 530 ms
X10 for T1 < 530 ms: no reset
HIGH
LOW

Function
13
NAE1045320 / 11.2011
2.6.4 Verifying proper functionality of and testing X12
After activating the self test sequence with control input X10, the charger shall monitor the correct
X12 functionality at the following points in time:
M1: X12, disabled at 0.3 seconds after rising edge e1 of X10
M2: X12, enabled at 0.5 seconds after falling edge e2 of X12
M3: X12, disabled at 1.8 seconds after falling edge e2 of X12
M4: X12, enabled at 2.3 seconds after falling edge e2 of X12
Control
input X10
Switching
output X12
Analog output X1
for reference only
Start of
self test
Apply test current
10mA/400Hz
time t[sec]
t = 0 4.6
Apply test current
22mA DC
5.6 6.6
End of
self test
= charger electroni
cs
check level
75μs
s5.0s3.0 1.8s
2.3s
e1
e2
530ms
11ms
M1 M2 M3 M4
600ms..850ms

Function
14 NAE1045320 / 11.2011
2.7 Starting sequence
The RCMB101 is supplied by an external power supply. Supply voltage fluctuations can influence
measurements. To exclude this effect (calibration is considerably affected!), the following starting se-
quence is applied:
The starting sequence of the module begins when a supply voltage of Us+ 5 V is applied. The mod-
ule switches the switching output X12 (Open Collector) to HIGH level. Once Us+ 11 V is reached, the
module starts calibration. It must be ensured that no residual current is flowing.
Once calibration is complete, the supply voltage measurement will be repeated. If the condition Us+
11 V is not met, calibration will be repeated.
The module next switches the switching output X12 to LOW level. Then the test winding is supplied
with current for 2s and the resultant measured value is output at X1 and the corresponding switch-
ing state is applied to X12.
If the control impulse at the input X10 is shorter than T = 50 μs, the input will be monitored until an
impulse T 50 μs is applied.
If the control impulse at the input X10 is at HIGH level for longer than T = 100 μs, residual current
measurement will start when a HIGH level is applied at the control input X10 for T5 5 ms.
If the control impulse at the input X10 is at HIGH level for T 5 ms, the control input will be scanned
again.
If the control impulse at the input X10 is at HIGH level for T = 50...100 μs, the residual current moni-
toring module will switch the switching output X12 to HIGH level after 10...11 ms. Both supply volt-
age measurement and calibration will be repeated.
Calibration starts after applying a HIGH level with a pulse duration of T2 = 50...100 μs at the control
input X10. If the condition of pulse duration is fulfilled, the module will switch the switching output
X12 to LOW level after 10...11 ms. Both the measurement of the supply voltage and calibration will
be repeated.
In this way, the pulse T2 can be used to test the switching output X12.
If the input is not connected (continuous HIGH level), ground fault current measurement will take
place 5 ms after the supply voltage has been tested.

Function
15
NAE1045320 / 11.2011
Starting sequence
2 s
Offset measurement
2 s
0,5 s
X12 = HIGH
Delay
X12 = LOW
0,05...0,1 ms
X12 = HIGH
10..11 ms
X10 < 50 μs
HIGH ?
No
Yes
X10 > 5 ms HIGH
?
No
Yes
US+ >= 11 V
?
Yes
Yes
No
No
US+ >= 11 V
?
X10 > 100 μs
HIGH ?
Yes
No
Us+ >= 5 V
?
No
Yes
Start I-measurement
Switch on test current
through test winding
Stop I-measurement
Switch off test current
through test winding
0,1 s
2,0 s
0,1 s
Start I-measurement

Function
16 NAE1045320 / 11.2011
2.8 Values outside the permissible measuring range
If the ground fault current exceeds the measuring range (20mA), the RCMB101 will switch the
Open-Collector output to HIGH once the measuring time T1 has elapsed.
In comparison to the switching output X12, the voltage at the analog output X1 increases with a de-
lay of Ux1 = 4.85 V within the time T2. The switching time T1 of the switching output X12 and the rise
time T2 of the voltage at the analog output X1 are dependent on the value of the ground fault cur-
rent. Refer to the legend of T1 and T2 of the diagram above.
After switching off the residual current 20 mA, the device stores the voltage value of the analog
output X1 and the status of the switching output X12 for the time T3 =1.2 s.
The level of the switching output X12 will only change to LOW when the ground fault current drops
to values 10mA.
Residual current dI
Switching output X12
Voltage output X1
4,85 V
T3 = 1,2 s
~ ~
0,15 V
~ ~
~ ~
T1
T2
Connecting residual current
T1: Switch-off (X12) time depending
upon the residual current according
to UL2231-2 minus 10ms to drive
a power connector:
T1[s] <= (20 / dI[mA] ) ^ 1,43  10ms
T2: Measuring time (X1) depending
upon the residual current :
T2  150 ms
T4
HIGH
LOW
20 mA

17
NAE1045320 / 11.2011
2.9 Measuring range and switching times
2.9.1 Measuring range
The measuring range of the ground fault current is 0…20mA according to UL 2231 for the type
CCID20.
2.9.2 Switching times without a contactor
The time the RCMB101 needs for signaling a disconnection with switching output X12 is at least
10ms below the disconnection time required by the UL 2231 standard.
Max. switching times of the output X12 depending on the ground fault current
Please consider that the actual interruting device/contactor chosen by the
charger manufacturer does not exceed disconnection time
of 10 ms !
t[ms]
dI[mA]
20 100
t  (20 / dI)
1,43
 10ms
10
0
0
300
90
990

Function
18 NAE1045320 / 11.2011
2.10 Fault detection and resulting reactions
Type of fault Detection Reaction
Wire break in the
current transformer
Frequency measurement
via CT test input
at the controller
X1 = 5.0 V
X12 = HIGH
Short-circuit in the
current transformer wind-
ing
Frequency measurement
via CT test input
at the controller
X1 = 5.0 V
X12 = HIGH
Constant output voltage at
the measuring oscillator
Frequency measurement
via CT test input
at the controller
X1 = 5.0 V
X12 = HIGH
Failure of the controller
clock
(Main Clock)
The internal computer
watchdog resets the device
X1 = 5.0 V or X1 = 0 V
X12 = HIGH
Supply voltage failure
Monitoring module con-
nects and disconnects resid-
ual current monitoring
X1 = 5.0 V or X1 = 0 V
X12 = HIGH
Open-Collector output con-
stantly at LOW level
While connecting the sup-
ply voltage, when checking
that the output switches to
HIGH for 4 s;
For details about time T4
refer to page 10
Detection by charging control
electronics after connecting
to supply voltage
Analog output constantly at
LOW level
Output voltage outside the
permissible voltage range
Disconnection of the charger
by operating control
Storage cell of the comput-
ing system defective
Detection by
memory self test
X1 = 5.0 V
X12 = HIGH
Loss of return addresses
from subprograms
Response of the internal
watchdog
X1 = 5.0 V or X1 = 0 V
X12 = HIGH

19
NAE1045320 / 11.2011
3. Installation and connection
3.1 Installation
Refer to dimension diagrams on page 23.
3.2 Terminal assignment
Plug designation Description
X1 Analog voltage output
X2 -US: Voltage supply -12 V / -15 V
via current limiting or 100 mA fuse recommended
X3 GND: ground
X4 not connected
X9 GND: ground
X10 Control input: 0...5 V
X11 +US: Voltage supply +12 V / +15 V
via current limiting or 100 mA fuse recommended
X12 Switching output/alarm output
(transistor, Open Collector)
If the supply voltages +Usand -Usat X2/X11 are outside the permissible
voltage range, the signals at the outputs X1 and X12 may be outside
the tolerance range!
X12 X3 X2 X1
X11 X10 X9 X4

Installation and connection
20 NAE1045320 / 11.2011
3.2.1 Conductor routing through current transformer
Only conductors insulated in conformance with the appropriate standards may be routed through
the current transformer. Ensure that all conductors are routed centrally through the current trans-
former.
3.3 Application examples
3.3.1 Contactor is controlled by charger electronics and switching output signal
Switching output X12 is used as hardware enable signal for the power contactor. Contactor is con-
trolled by charger electronics software. Switching output X12 and analog output X1 are monitored
by charger to verify that X1 and X12 show consistent information and that the behavior after a test
(initiated with X10) is correct.
3.3.2 Contactor is controlled by charger electronics
Contactor controlled by charger electronics software. Switching output X12 and analog output X1
are monitored by charger to verify that X1 and X12 show consistent information and that the behav-
iour after a test (initiated with X10) is correct.
Make sure to select a relay and a relay driver circuit with a release time of less
than 10 ms under nominal load condition of the charger.
Mains
Charger
Control Electronics
RCMB101
Us+
Us-
GND
X12 X10X1
Power
Contactor
to Load cable
Driver Circuit
&
Supply
Switching
Output
Analog
Output
enable
Control
Input
Mains
Charger
Control Electronics
RCMB101
Us+
Us-
GND
X12 X10X1
Power
Contactor
to Load cable
Driver Circuit
Supply
Switching
Output
Analog
Output
Control
Input