Gossen MetraWatt PROFITEST H+E BASE User manual

Operating Instructions
PROFITEST H+E BASE
Diagnostics Unit for Electric Charging Stations
(Type 2 Connector Socket) 3-349-876-03
1/3.16
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Operating Instructions PROFITEST H+E BASE
Page 1
Table of Contents
General Notes ......................................................................................................................................1
Explanation of Symbols........................................................................................................................1
Basic Safety Precautions ......................................................................................................................2
Product Overview.................................................................................................................................3
Initial Start-Up......................................................................................................................................9
Diagnosis of Charging Points with the Diagnostics Unit ....................................................................10
Language Selection ............................................................................................................................13
Errors..................................................................................................................................................14
Maintenance ......................................................................................................................................14
Technical Data....................................................................................................................................14
Appendix: Practical Information on Testing Charging Points ............................................................15
General Notes
These operating instructions include important information about your device’s features and its
use. Before using the device, read the instructions carefully and familiarize yourself with its
operation. Keep these operating instruction in a safe place.
Explanation of Symbols
This product fulfills guidelines in accordance with 89/336/EEC.
Warning regarding property damage. Safety precautions must be adhered to.
Warning regarding personal injury. Safety precautions must be adhered to.
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Operating Instructions PROFITEST H+E BASE
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Basic Safety Precautions
Guarantee
No guarantee is made with regard to function and safety unless the warnings and safety
precautions included in these operating instructions are observed.
GMC-I Messtechnik GmbH assumes no liability for personal injury or property damage which
occurs due to non-observance of the warnings and safety precautions.
Use for Intended Purpose
The diagnostics unit is intended exclusively for examining the functional performance of
charging stations for electric vehicles with type 2 connector socket (mode 3 charging). Use for
other purposes is prohibited.
Target Group
Only trained, qualified electricians may use the PROFITEST H+E BASE diagnostics unit.
Trained, qualified electricians fulfill the following requirements:
Knowledge of general and specific accident prevention regulations
Knowledge of applicable electrotechnical regulations
Training in use and care of appropriate safety equipment
Ability to recognize hazards associated with electricity
Warning!
Danger!
The diagnostics unit may only be used at charging points which are tested in accordance with
VDE 0100.
The unit is intended solely for the purpose of diagnostics and cannot be used as a substitute for a
corresponding test instrument!
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Operating Instructions PROFITEST H+E BASE
Page 3
Product Overview
Scope of Delivery
PROFITEST H+E BASE diagnostics unit
Two 9 V block batteries
12 V power pack
Operating instructions
Device Layout
Key
1Protective cover
2Power pack connector socket (12 V, 1 A)
3Battery compartment for two 9 V block batteries
4Control panel
5Carrying handle
6230 V earthing contact socket for connecting a test consumer
7Type 2 charging plug for connection to the charging point
1
2
3
4
7
5
6
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Operating Instructions PROFITEST H+E BASE
Page 4
Control Panel Layout
Key
1Rotary mode selector switch and OK button
2Rotary status selector switch and escape button
3Off button
4On button (the button has to be pressed and held for several seconds in order to switch
the unit on)
5Display
6USB port
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Operating Instructions PROFITEST H+E BASE
Page 5
Display Layout
The display is subdivided into various blocks:
1Vehicle States
2Cable Condition
3Error States
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Operating Instructions PROFITEST H+E BASE
Page 6
4PWM Signal Evaluation
5Phases and Phase Sequence
6Battery Level
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Operating Instructions PROFITEST H+E BASE
Page 7
Displays
The following symbols with the meanings shown below can appear at the display:
Vehicle States
No vehicle connected
Vehicle connected
Vehicle not ready
Vehicle ready to charge
No ventilation required
Ventilation required
Cable Condition
No cable
13 A cable
20 A cable
32 A cable
63 A cable
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Operating Instructions PROFITEST H+E BASE
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Error States
Diode OK
Diode short-circuited
CP OK
CP short-circuited to PE
No RCD tripping
RCD tripping
Phases and Phase Sequence
Phase L1 switched on
Phase L2 switched on
Phase L3 switched on
Clockwise phase sequence
Counterclockwise phase sequence
Battery Level
Battery full
Battery depleted
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Operating Instructions PROFITEST H+E BASE
Page 9
Initial Start-Up
General
Warning!
Danger!
The device should be checked to assure that it’s in good condition before initial start-up.
The device may only be used by trained personnel.
Inserting the Batteries
The device can be operated with two rechargeable or regular 9 V block batteries. The two battery
compartments (3) on the right side of the device are opened in order to insert the batteries.
Battery polarity is identified in the battery compartment.
Warning!
It is absolutely essential to assure that battery polarity is not reversed.
The battery compartments are closed after the batteries have been inserted.
Only high quality regular or rechargeable batteries should be used!
Connecting the Power Pack
A 12 V power pack is included in scope of delivery of the diagnostics unit. The device can be
operated with either batteries or the power pack.
The power pack is connected by inserting its plug into the socket (2) at the right side of the device.
The batteries are disconnected from supply power when the power pack is connected.
Warning!
Use only the included power pack in order to avoid damage to the diagnostics unit!
Switching the Diagnostics Unit On
The on button (4) is pressed and held for about 4 seconds in order to switch the diagnostics unit
on. A start-up message appears. As soon as the start-up message is replaced with the normal
display (see page 5), the on button (4) can be released.
Switching the Diagnostics Unit Off
Briefly press the off button (3) in order to switch the device off.
The device is switched off after about 10 minutes if neither of the rotary switches (1 and 2) has
been activated during this time. Display illumination is switched off after just 30 seconds.
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Operating Instructions PROFITEST H+E BASE
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Connecting a Test Consumer
The diagnostics unit is equipped with an earthing contact socket (6) to which a test consumer can
be connected. Any desired test consumer (230 V, max. 13 A) can be connected in order to test a
charging point under load.
Connecting the Diagnostics Unit to a Charging Point
The diagnostics unit is equipped with a type 2 plug (7) for connection to the charging point. This
can be plugged into the charging point.
Diagnosis of Charging Points with the Diagnostics Unit
Charging points can be tested in accordance with IEC 61851 with the help of the PROFITEST H+E
BASE diagnostics unit.
The diagnostics unit makes the following functions available:
Vehicle Simulation (CP)
States A, B, C and D can be simulated in accordance with IEC 61851. Symbols corresponding to the
various vehicle states appear at the display (see pages 6 and 8).
Display
Status
Voltage U/L
Meaning
A
+12 V ... -12 V
No vehicle
B
+9 V ... -12 V
Vehicle connected
C
+6 V ... -12 V
Ready without
ventilation
D
+3 V ... -12 V
Ready with ventilation
Cable Simulation (PP)
The various codings for charging cables with 13, 20, 32 and 63 A can be simulated. It’s also
possible to simulate the “no cable” state. (see pages 6 and 8)
The various charging cables are simulated by connecting different resistances between PP and PE.
The following values are possible in accordance with IEC 61851:
Display
Resistance
Max. Permissible Current
None
No cable
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Operating Instructions PROFITEST H+E BASE
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1.5 KΩ
13 A
680 Ω
20 A
220 Ω
32 A
100 Ω
63 A
Fault Simulation
The diagnostics unit is equipped with an option for simulating common errors (see pages 6 and 9).
These include:
Short-circuiting of the diode in the vehicle’s circuit
Short-circuit between CP and PE
Residual current between L1 and PE (via a 6.8 K resistor)
The charging point’s reaction can be observed after triggering the various errors.
Display
Simulated Error
No error
Short-circuited diode
CP-PE short-circuit
Residual current between L1 and PE
Evaluation of the PWM Signal
Evaluation of the PWM signal provides information concerning the functionality of PWM
communication between the vehicle and the charging point. Correct charging is only possible with
error-free communication. The following PWM signal data are displayed for the purpose of
diagnostics (see page 7):
Positive voltage
State A, + 12 V, no vehicle
State B, + 9 V, vehicle connected
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Operating Instructions PROFITEST H+E BASE
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State C, + 6 V, vehicle ready for charging without ventilation
State D, + 3 V, vehicle ready for charging with ventilation
Negative voltage
In the event of correct functioning, voltage is - 12 V. If the diode is short-circuited (by means of
simulation), negative voltage is the same as positive voltage (but with the opposite preceding
sign).
PWM frequency
The valid PWM frequency should be 1000 Hz.
Charging current
Displayed charging current is calculated from the duty cycle (see explanation under duty cycle).
Duty cycle
In accordance with IEC 61851 the charging point communicates the maximum permissible
charging current to the vehicle via the duty cycle. Charging current is calculated automatically by
the diagnostics unit and displayed. The following table is specified by IEC 61851:
Duty Cycle
Maximum Charging Current or Meaning
< 3%
Charging not permissible
3% ≤ duty cycle ≤ 7%
Increased communication
7% ≤ duty cycle ≤ 8%
Charging not permissible
8% ≤ duty cycle ≤ 10%
6 A
10% ≤ duty cycle ≤ 85%
Max. charging current = (% duty cycle) * 0.6 A
85% ≤ duty cycle ≤ 96%
Max. charging current = (% duty cycle -64) * 2.5 A
96% ≤ duty cycle ≤ 97%
80 A
Duty cycle > 97%
Charging not permissible
Turn-off time T-off
Turn-off time T-off is the time which elapses between triggering of a shutdown condition and
interruption of all 3 phases. (Caution! Realistic values are only displayed for 3-phase charging.)
Shutdown conditions represent a transition from state C or D to state A or B, as well as triggering
of an error.
In accordance with IEC 61851, turn-off time must be less than 100 ms.
Phases and Phase Sequence
The symbols for the phases (see page 7) indicate whether or not phases L1, L2 and L3 are switched
on. The respective symbols appear when the phases are switched on. As soon as all 3 phases are
switched on, the direction of phase rotation is displayed (clockwise or counterclockwise).
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Operating Instructions PROFITEST H+E BASE
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Operating the Diagnostics Unit with the Rotary Switches
The two rotary switches (1 and 2) are used to operate the diagnostics unit.
The device is switched from one mode to the other by turning the rotary mode selector switch (1).
The respectively active more is indicated by means of a blinking display.
As shown on page 6, there are 3 operating modes:
Vehicle states
Cable condition
Error states
Within each operating mode, the respective state is selected by turning the rotary status selector
switch (2).
The selection of error states with the rotary switch must also be subsequently acknowledged by
pressing and holding the OK button (1) for about 4 seconds. An acoustic signal is generated when
the error has been successfully triggered. The error state is then retained until it’s cleared by
turning the rotary status selector switch (2).
Battery Display
Adequate battery voltage is imperative for testing the PWM signal. For this reason the diagnostics
unit is equipped with a simple battery voltage display.
The symbol indicates whether or not battery voltage is adequate for proper diagnosis.
As soon as “battery depleted” is indicated (see also page 9), diagnosis is no longer possible.
“Battery full” is indicated when the power pack is connected.
USB Port
The USB port is used to install firmware updates and (depending on software version) to transmit
diagnostics results to a connected PC.
Warning!
Danger!
The USB port may not be connected to a PC or a notebook while a charging point is being
diagnosed!
Language Selection
Upon shipment from the factory, the user interface language of the diagnostics unit is set to
German. Additional languages are also available. The device must be switched off in order to
select a different language.
In order to select a language, press and hold the escape button (2). Then simultaneously press and
hold the on button (4). The currently selected language is then indicated at the display (5). The
desired language can then be selected by turning the rotary mode selector switch (1) and
acknowledged by pressing the OK button (1). The diagnostics unit is then restarted automatically
with the selected language.
The selected language is retained until a different language is once again selected.
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Errors
Error
Cause
Required Action
After being switched on, the
device switches itself back off
again.
On button not pressed long
enough.
Press and hold the on button
until the device remains on.
The device does not respond
when the on button is pushed.
No batteries are installed or
the batteries are depleted.
Install new batteries or use the
power pack.
The device indicates incorrect
values for PWM voltage.
Battery depleted
Observe the battery display
and install new batteries if
necessary.
Maintenance
Due to the device’s characteristics, no maintenance should be carried out by the user. If repairs
should become necessary, please contact our repair and replacement parts service department
(see address on back cover).
Outside surfaces may only be cleaned with a dry, lint-free cloth.
Danger!
No liquids may be permitted to penetrate into the device’s interior or the plug connectors.
Technical Data
Input voltage 400 V (3-phase)
Frequency 50 Hz
Test consumer power Max. 2.9 kVA
Electrical Safety
Protection class I
Nominal voltage 400 V DC
Test voltage 500 V DC
Measuring category CAT III, 300 V
Pollution degree 2
Ambient Conditions
Operating temperature -10 to 45 °C
Storage temperature -25 to 60 °C
Relative humidity Up to 80% (no condensation)
Mechanical Design
Dimensions (W x L x H) 200 x 240 x 115 mm
Weight 2.35 kg
Protection IP 21
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Operating Instructions PROFITEST H+E BASE
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Appendix: Practical Information on Testing Charging Points
Type II Plug for Mode 3 Charging
Source: Mennekes
Resistance Coding for Charging Cables
Table B.101 – Resistor Codings for Plugs
Current capacity of the cable assembly
Nominal resistance of Rc
Tolerance 3% 3
Recommended
interpretation range
by the EVSE
13 A
1.5 k0.5 W 1, 2
> 1 k- 2.7 k
20 A
680 0.5 W 1, 2
330 -1 k
32 A
220 0.5 W 1, 2
150 -330 
63 A (3-phase) /
70 A (1-phase)
100 0.5 W 1, 2
75 -150 
Interrupt power supply
< 75 
1The power dissipation of the resistor caused by the detection circuit shall not exceed the value given above.
The value of the pull-up resistor shall be chosen accordingly.
2Upon circuit failure mode, resistors used should preferably fail such that the resistance value rises.
Metal film resistors commonly show acceptable properties for this application
3Tolerances to be maintained over the full useful life and under environmental conditions as specified by the
manufacturer.
Source: IEC 61851
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Operating Instructions PROFITEST H+E BASE
Page 16
Typical Pilot Electric Equivalent Circuit
for Mode 3 Charging
Typical pilot electric equivalent circuit
Source: IEC 61851
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Operating Instructions PROFITEST H+E BASE
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Typical Pilot Electric Equivalent Circuit
for Mode 3 Charging
Table A.2 – Vehicle Control Pilot Circuit Values and Parameters
(see figures A.1 and A.2)
Parameter
Symbol
Value
Value Range
Units
Permanent resistor value
R2
2,740
2658 - 2822

Switched resistor value for vehicles
not requiring ventilation
R3
1,300
1261 - 1339

Switched resistor value for vehicles
requiring ventilation
R3
270
261.9 - 278.1

Equivalent total resistor value
no ventilation (Figure A.2)
Re
882
856 - 908

Equivalent total resistor ventilation
required (Figure A.2)
Re
246
239 - 253

Diode voltage drop
(2.75 – 10 mA, -40 °C to +85 °C
Vd
0.7
0.55 – 0.85
V
Maximum total equivalent input capacity
Cv
2,400
N/A
pF
Value ranges are to be maintained over full useful life and under design environment conditions.
Note: 1% resistors commonly recommended for this application
Source: IEC 61851
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System States –PWM Voltage
Table A.3 – System States
System
state
EV
connected
to the
EVSE
S2
EV
ready to
receive
energy
EVSE
ready
to
supply
energy
EVS
supply
energy
Vaa
Remark
High
level
Low
level
A1
no
N/A
no
not
ready
off
12 Vd
N/A
Steady
voltage
Vb= 0 V
A2
no
ready
off
12 Vd
-12 Ve
PMW
B1
yes
open
no
not
ready
off
9 Vb
N/A
Steady
voltage
R2 detected
B2
no
ready
off
9 Vb
-12 Ve
PMW
C1
yes
closed
yes
not
ready
off
6 Vc
N/A
Steady
voltage
R3 = 1.3 k3%
Charging area
ventilation not
required
C2
yes
ready
off
6 Vc
-12 Ve
PMW
D1
yes
not
ready
off
3 Vc
N/A
Steady
voltage
R3 = 270 3%
Charging area
ventilation
required
D2
yes
ready
off
3 Vc
-12 Ve
PMW
E
yes
N/A
no
not
ready
off
0 V
Steady
voltage
Vb= 0: EVSE or
utility problem or
utility power not
available or pilot
short to earth
F
yes
N/A
no
not
ready
off
N/A
-12 V
Steady
voltage
EVSE not
available
aAll voltages are measured after stabilization period.
bThe EVSE generator may apply a steady- state DC voltage or a +12 V square wave during this period.
The duty cycle indicates the available current as in Table A.5.
cThe voltage measured is a function of the value of R3 in Figure A.1 (indicated as Re in Figure A.2).
d12 V static voltage
eThe EVSE shall check pilot line low state of -12 V, diode presence, at least at the transition between B1 and B2
(or at least once before the closing of the supply switch on the EVSE).
The state changes between A, B, C and D are caused by the EV, the state changes between 1 and 2 are created by
the EVSE.
Source: IEC 61851
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Operating Instructions PROFITEST H+E BASE
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System States – PWM Voltage
Table A.201 – Pilot Voltage Range
The following table details the pilot voltage range as a result of tables A.1 and A.2 components
values. These voltage ranges applies to the EVSE (Va).
Nominal voltage range imposed
by the system
Acceptable voltage range
recognized to detect the states a
State / Range
Minimum
[V]
Nominal
[V]
Maximum
[V]
Minimum
[V]
Nominal
[V]
Maximum
[V]
States A1, A2 /positive
11.4
12
12.6
11
12
13
States B1, B2 /positive
8.37
9
9.59
8
9
10
States C1, C2 /positive
5.47
6
6.53
5
6
7
States D1, D2 /positive
2.59
3
3.28
2
3
4
State E
0
0
1
-1
0
1
States A2, B2, C2, D2/
negative
State F a
-12.6
-12
-11.4
-13
-12
-11
a applicable to Va only
Note: the EVSE may also be designed to use the voltage of the internal generator (Vg) as a reference. The valid voltage
ranges are then to be calculated as given in the following table. These ranges are identical to the values in the above
table for Vg=12 V.
Source: IEC 61851
System States –PWM Voltage
State A State B State C State D State X
State A: No vehicle connected
State B: Vehicle connected but not ready for charging
State C: Vehicle ready for charging without ventilation
State D: Vehicle ready for charging with ventilation
State X: Error
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