Fluke FEV100 User manual

FEV100
Electrical Vehicle Charging
Station Test Adapter
Users Manual
PN 5278136, April 2021
© 2021 Fluke Corporation. All rights reserved.
Specications are subject to change without notice.
All product names are trademarks of their respective companies.

1
Symbols
Symbol Description
WWARNING. RISK OF DANGER.
XWARNING. HAZARDOUS VOLTAGE. Risk of electric shock.
Consult user documentation.
TDouble Insulated.

Measurement Category II is applicable to test and measuring
circuits connected directly to utilization points (socket outlets
and similar points) of the low-voltage MAINS installation.
JEarth.
PE Protective Earth.
CP Control Pilot.
Vehicles not requiring ventilation for indoor charging areas.
Vehicles requiring ventilation for indoor charging areas.

This product complies with the WEEE Directive marking
requirements. The a󰀩xed label indicates that you must not
discard this electrical/electronic product in domestic household
waste. Product Category: With reference to the equipment
types in the WEEE Directive Annex I, this product is classed as
category 9 "Monitoring and Control Instrumentation" product.
Do not dispose of this product as unsorted municipal waste.
Table 1. Symbols
Introduction
The FEV100 (the Product) tests the function and safety of AC charging
stations Level 2 (208 V AC or 240 V AC) and Level 1 (120 V AC). With this
adapter, charging stations are tested in accordance with SAE J1772.
The adapter imitates a car and opens up a charging cycle (activate voltage/
current output). Use additional test and measurement equipment, such as
but not limited to: Multimeters, Clamps, Insulation testers or Multifunction
Testers, to test a charging station. In addition, the adapter has a built in quick
safety test that does not require separate equipment.
Contact Fluke
Fluke Corporation operates worldwide. For local contact information, go to
our website: www.uke.com
To register your product, view, print, or download the latest manual or manual
supplement, go to our website.
Fluke Corporation
P.O. Box 9090
Everett, WA 98206-9090
[phone]
uke-info@uke.com

2
Safety Information
A Warning identies conditions and procedures that are dangerous to the
user. A Caution identies conditions and procedures that can cause damage
to the Product or the equipment under test.
WX Warning
To prevent the possibility of electric shock or personal injury:
• Read all safety information before you use the Product.
• Do not alter the Product and use only as specied, or the
protection supplied by the Product can be compromised.
• Carefully read all instructions.
• Do not touch voltages >30 V ac rms, 42 V ac peak, or 60 V dc.
• Before each use, examine the Product. Look for cracks or missing
pieces of the Product and cable assembly insulation. Also look for
loose or weakened components. Carefully examine the insulation
around the cable assembly connector.
• Only connect the Product to the charging stations as indicated in
the Specication section.
• Use the Product within the operating range only. The operating
range is specied in the Specication section.
• Do not touch any part of charging station during the GFCI test.
The GFCI test may place hazardous voltage onto conductive parts
of the charging station during the test if the charging station is
not properly grounded.
• Do not use the Product around explosive gas, vapor, or in damp
or wet environments.
• Do not apply more than the rated voltage, between the terminals
or between each terminal and earth ground.
• Use the correct terminals, function, and range for measurements.
• Do not use the Product if it operates incorrectly.
• Do not operate the Product with covers removed or the case
open. Hazardous voltage exposure is possible.
• Use only specied replacement parts.
• Do not use the Product if it is altered or damaged.
• Have an approved technician repair the Product.

3
Transport and Storage
Please keep the original packaging for future transport (for example if
calibration is necessary). Any transport damage due to faulty packaging will
be excluded from warranty claims.
The adapter must be stored in dry, closed areas. In case of the adapter being
transported in extreme temperatures, a minimum recovery time of 2 hours is
required prior to any operation.
Available Measurements
• Grounding system Pre-Test (veries that there is no presence of dangerous
voltage at the Ground terminal)
• Phase indicator (presence of voltage)
• CP State simulation (A, B, C , D ) for Control Pilot
• CP Error “E” simulation (Control Pilot CP signal short-circuited to PE)
• GFCI ground fault circuit interrupter test
• Fault Voltage test in normal conditions (no GFCI test current) and
during GFCI test
• PE Error (Earth Fault) simulation (interruption of PE conductor)
• Measurements on live conductors (L1, L2/N) and on PE ground
conductor
• Test of Control Pilot CP signal
Kit Components
The FLK-FEV100/TY1 Kit contains the following items:
1 FLK-FEV100/BASIC Test Adapter
1 FLK-FEV-COM/TY1 Type 1 Connector & Cable
1 Soft Carrying Case
1 Users Manual

4
Description of Warning Marks on Front Panel
1 Terminals with low voltage
output (approx. ±12 V) powered
by the charging station. Terminal
marked with Jis connected to
PE. Use for test purposes only.
The CP Signal Output terminals
can be hazardous if there is
a charging station error or
incorrect wiring.
2High danger of electric shock
is present when PE Pre-Test
indicator illuminates while
performing PE pre-test (see
Grounding protection Pre-Test).
In this case, stop testing
immediately. Make sure to
ground your body su󰀩ciently
while doing this test.
Figure 1. Front panel warning marks
3
2
1
3 Dangerous voltages can be present at L1, L2/N, and PE terminals while
the test adapter is plugged into the charging station. Use the test sockets
for test purposes only. Do not supply any appliance or charge an electric
vehicle via these connectors. Terminals N and PE can be hazardous if
there is a charging station error or incorrect wiring.
Operation Elements and Connectors
Figure 2. Front panel function
1
2
3
4
5
6
7
8
9
10
11
1CP Error “E” button
2Protective Grounding
test JPre-Test
warning indicator
3Protective Grounding
JPre-Test touch
probe
4Measurement
terminals L1, L2/N
5Voltage presence
indicator
6Measurement Ground
terminal
7Grounding error
simulation button
8GFCI test button and
green READY indicator
9CP State rotary
switch selector
(A, B, C , D )
10 Test cable input with 5-pole male connector
11 Test cable for specic EV charging station (Type 1 or Tesla)

5
1Test cable input
2CP Signal output terminal (yellow)
3CP Signal output terminal
(connected to PE) (green)
Figure 3. Top of the Product
123
Figure 4. Back of the Product
Testing Charging Stations
WX Warning
To prevent possible electric shock, re, or personal injury:
• Before starting any tests, the operator must be familiar with
the standard: SAE J1772, “SAE Electric Vehicle and Plug in
Hybrid Electric Vehicle Conductive Charge Coupler” and the
documentation of the charging station in use.
• Before starting any tests, refer to the local regulations and
standards for: safety at work and any relevant publications from
the Health and Safety Executive.
• Only skilled persons, competent in verication and the types of
tests suitable for installations and charging stations, should do
the tests.
• If the wrong types of tests are done or if testing is done in an
incorrect sequence then a potentially hazardous situation can
occur for both the operator and the DUT (Device Under Test).
• The operator must fully understand the various tests required and
how they should be done.
• The charging station must pass the Protective Earth (Ground) PE
Pre-Test prior to the operator touching exposed metal surfaces or
any other test. If the PE Pre-Test fails, stop further testing. Resolve
any faults before proceeding. In case of error, all metal parts of
the charging station including output terminals and PE can have
hazardous voltage. In this case, there is a high risk of electric
shock to the operator and other persons nearby.
• The PE Pre-Test detects the presence of hazardous voltage on
Protective Earth but may not detect an open Protective Earth.
Testing a charging station
To test the charging station:
1. Do a safety grounding protection pre-test (to verify that no dangerous
voltage is present in the grounding circuit due to possible miswire or
electrical wiring or grounding malfunction).
2. Verify station output voltage using an additional meter.

6
3. Verify station maximum preset charge current using CP terminals and
a meter with duty cycle function or an oscilloscope.
4. Simulate the error states as described in the SAE J1772 standard: CP
Error “E”, GFCI trip test, and Grounding Error.
Additional advanced tests such as Insulation Resistance, Power Quality,
Analysis of the Control Pilot waveform, and Loop Impedance can also be
done using the adapter in conjunction with appropriate test and measurement
equipment. The adapter is compatible with Fluke and Amprobe test and
measurement instrumentation.
Grounding protection Pre-Test
The Grounding J Pre-Test safety feature allows the operator to test the
PE conductor for possible presence of dangerous voltage against earth. In
normal circumstances, the grounding conductor is connected to earth and
therefore has no voltage against earth. However, if the grounding conductor
is not connected to earth (for example, connected to phase by mistake or the
grounding wire is disconnected or broken) the situation may be hazardous.
Operator skin contact is required on the PE PRE-TEST button (do not wear
gloves) as well as a suitable operator reference to a known earth ground
(through the operator's shoes etc.) Do not touch any metal parts of the
charging station while performing this test. In case of improper connection to
earth (for example, isolated placement of your body) this indication may be
not reliable.
WX Warning
The PE Pre-Test detects the presence of hazardous voltage on
Protective Earth but may not detect an open Protective Earth.
Test procedure:
1. Connect the test adapter to the charging station.
2. Touch the probe with a bare nger. If PE Light (item 2, Figure 2) is
illuminated, then dangerous voltage is present at ground conductor.
Stop further testing immediately and check for a possible wiring fault of
the tested ground conductor. In case of this error, the ground terminal
carries hazardous voltage. There is a high risk of electric shock.
Possible errors are:
• PE interrupted / not connected
• PE carries voltage (for example, connected to phase)
Verifying charging voltage - vehicle simulation
Use the CP State rotary switch selector, to simulate various vehicle states
when the test adapter is connected to the charging station. Vehicle states
are simulated with di󰀨erent resistances connected between CP and PE
conductors. Correlation between resistance and vehicle states is shown in
Table 2 below.
Marking
of Vehicle
State
Electric Vehicle (EV)
State
Resistance
between CP
and PE
Voltage at
CP terminal
A EV not connected Open (∞)±12 V
1 kHz
BEV connected, not ready
to charge 2.74 kΩ +9 V / -12 V 1 kHz
C
EV connected, ventilation
not required, ready to
charge
882 Ω +6 V / -12 V
1 kHz
DEV connected, ventilation
required, ready to charge 246 Ω +3 V / -12 V 1 kHz
Table 2. Correlation between resistance, vehicle state and CP voltage signal.

7
Initiating a charging cycle:
1. Connect the adapter cable to the charging station.
2. Turn a CP switch to B position and wait 3 to 5 seconds – in commercial
stations this may initiate a station to ask for payment information
3. Turn a CP switch to either C or D position depending on the type of
station you are testing (respectively with or without indoor charging
area ventilation requirement) to open the charging cycle.
Note
If the station does not begin the charging cycle, turn the CP switch
to position A. Then turn the CP switch to position B and wait 3 to
5 seconds. Then turn the CP switch to position C or D. Some EV
charging stations require a time delay to establish a proper connection
when CP State B is selected.
The red LED indicates that the charging station opened for the charging cycle
and voltage is present at the adapter terminals. The green READY indicator
should light up to indicate that the GFCI test circuit is ready for testing.
Measuring terminals of the adapter are directly connected to Phase 1 (L1),
Phase 2 (L2/N) or N (L2/N), and PE conductors of the charging station via
the test cable. Use these terminals for measuring purposes only. Do not use
the terminals to supply power to any other equipment.
Connect a meter to the L1 and L2/N terminals to perform output voltage
measurement. The terminals can be also used to perform other tests (for
example the loop impedance or Power Quality).
Verication of the charging station’s preset maximum charging current
and CP signal
The purpose of the CP function is communication between a vehicle and
charging station. The duty cycle of the PWM Pulse Width Modulation signal
denes the maximum available charging current.
CP output terminals are connected to CP and Ground conductors of the
charging station under test via the test cable. The green socket is connected to
Ground. These outputs are for connection of a meter with a duty cycle function
or an oscilloscope to check the waveform and amplitude of the CP signal.
For details of communication protocol refer to SAE J1772 and the
documentation of the manufacturer of the charging station.
Verication of the maximum charging current with a multimeter
Set a maximum charging current of the charging station using the internal
switch. The value of the maximum charging station current cannot exceed
the max current allowed by the gauge of the installed electrical wires and
breaker according to the National Electrical Code.
Testing maximum charging current:
1. Connect adapter to the charging station and select either state C or
D using rotary switch depending on the type of station to start the
charging cycle.
2. Connect meter set to Duty Cycle to the Control Pilot (CP) terminals
located on the top of the adapter. See Figure 3, use items 2and 3.
Make sure to connect COM input of the meter to the Green (Ground)
output of the CP terminal.
3. Read the duty cycle value and translate to maximum charging
current using the below formulas or a quick reference table (based on
J1772 standard).
Note
• Do not connect to L1, L2/N terminals.
• Connect the multimeter test leads after the charging station starts the
charging cycle. In some situations, the meter can inuence the CP
signal, and prevent the station from starting the charging cycle.

8
9.5 % ≤ Duty Cycle < 10 %, Maximum current = 6 A
10 % ≤ Duty Cycle ≤ 80 %, Maximum current = (duty cycle %) x 0.6
85 % < Duty Cycle ≤ 96 %, Maximum current = (duty cycle % - 64) x 2.5
96 % < Duty Cycle ≤ 96.5 %, Maximum current = 80 A
See detailed calculations in Table 3 below.
Duty Cycle (%) Max
Amps Duty Cycle (%) Max Amps Duty Cycle (%) Max Amps
9.5 6.0 40 24.0 70 42.0
10 6.0 41 24.6 71 42.6
11 6.6 42 25.2 72 43.2
12 7.2 43 25.8 73 43.8
13 7.8 44 26.4 74 44.4
14 8.4 45 27.0 75 45.0
15 9.0 46 27.6 76 45.6
16 9.6 47 28.2 77 46.2
17 10.2 48 28.8 78 46.8
18 10.8 49 29.4 79 47.4
19 11.4 50 30.0 80 48.0
20 12.0 51 30.6 81 48.6
21 12.6 52 31.2 82 49.2
22 13.2 53 31.8 83 49.8
23 13.8 54 32.4 84 50.4
24 14.4 55 33.0 85 51.0
25 15.0 56 33.6 86 55.0
26 15.6 57 34.2 87 57.5
27 16.2 58 34.8 88 60.0
28 16.8 59 35.4 89 62.5
29 17.4 60 36.0 90 65.0
30 18.0 61 36.6 91 67.5
31 18.6 62 37.2 92 70.0
32 19.2 63 37.8 93 72.5
33 19.8 64 38.4 94 75.0
34 20.4 65 39.0 95 77.5
35 21.0 66 39.6 96 80.0
36 21.6 67 40.2 96.5 80.0
37 22.2 68 40.8
38 22.8 69 41.4
Table 3. Calculations of max. charging current on basis of duty cycle.
Error states:
Duty Cycle = 0 % (Duty Cycle < 3 %), State F or E (see SAE J1772
Standard); no charging allowed
Duty Cycle = 5 % (4.5 % ≤ Duty Cycle ≤ 5.5 %), Indicates that digital
communication is needed
7 % < Duty Cycle < 8 %, Error state; no charging allowed
Duty Cycle = 100 %, State B1, C1 or D1; no charging allowed

9
CP Error “E” simulation
The standard SAE J1772 denes Error “E” as a state when charging station
is: disconnected from vehicle, disconnected from utility, there is a loss of
utility power or control pilot is short to control pilot reference (ground).
To simulate the CP Error “E”:
1. Push and hold CP Error “E”.
2. While holding the CP Error “E” button turn the CP rotary switch to
either C or D position.
3. The station should NOT open the charging cycle and a new charging
process should be prevented.
Note
The charging station is not required to actively generate the error
code, so the active charging process will not be interrupted if CP Error
“E” button is pushed after the charging cycle is initiated.
GFCI test
Each charging station is required to be equipped with GFCI protection. On
many stations the GFCI protection is fully automatic and does not need a
manual reset after the GFCI circuit is tripped.
Testing a GFCI protection:
1. Turn the CP switch to either C or D position depending on the type of
station you are testing (respectively with or without indoor charging
area ventilation required) to open the charging cycle.
2. The green READY indicator next to GFCI test button illuminates.
If the READY indicator blinks before you press the GFCI test button,
then fault voltage is higher than 45 V at the PE terminal. Check and
improve the grounding system before you do further tests.
WX Warning
Do not touch any part of charging station during the GFCI test.
The GFCI test may place hazardous voltage onto conductive parts
of the charging station during the test if the charging station is not
properly grounded.
3. Press the GFCI test button.
The station should terminate a charging cycle as soon as the GFCI
button is pressed.
If the READY indicator starts to blink after you press the GFCI test
button, then fault voltage during GFCI test was higher than 45 V. The
fault voltage was caused by the test current. Check and improve the
grounding system before you do further tests.
4. Unplug the adapter to reset the GFCI protection, if necessary.
Ground Error (Ground Fault) simulation
The Ground JError button simulates an interruption of the ground
conductor. As a result, the pending charging process is aborted, and new
charging processes are prevented.