Gossen MetraWatt PROFITEST H+E TECH User manual

Operating Instructions
PROFITEST H+E TECH
Diagnostics Unit for Electric Charging Stations
(Type 2 Connector Socket and Plug) 3-349-878-03
1/3.16
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Operating Instructions PROFITEST H+E TECH
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 the Charging Point and the Vehicle with the Inline Tester ...........................................10
Language Selection ............................................................................................................................12
Errors..................................................................................................................................................13
Maintenance ......................................................................................................................................13
Technical Data....................................................................................................................................13
Appendix: Practical Information on Testing Charging Points ............................................................14
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 TECH
Page 2
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 inline tester 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 TECH inline tester.
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 inline tester 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 TECH
Page 3
Product Overview
Scope of Delivery
PROFITEST H+E TECH inline tester
Two 9 V block batteries
12 V power pack
Operating instructions
Device Layout
Key
1Protective cover
2Power pack connector socket (12 V, 1A)
3Battery compartment for two 9 V block batteries
4Control panel
5Carrying handle
6Cable outlet with type 2 charging socket for connection to the vehicle
7Cable outlet with type 2 charging plug for connection to the charging point
2
1
3
4
5
6
7
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Operating Instructions PROFITEST H+E TECH
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 TECH
Page 5
Display Layout
The display is subdivided into various blocks:
1Vehicle States
2Cable Conditions
3Error States
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Operating Instructions PROFITEST H+E TECH
Page 6
4PWM Signal Evaluation
5Phases and Phase Sequence
6Battery Level
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Operating Instructions PROFITEST H+E TECH
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 TECH
Page 8
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 TECH
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 inline tester. 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 inline tester!
Switching the Inline Tester On
The on button (4) is pressed and held for about 4 seconds in order to switch the inline tester 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 Inline Tester 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 TECH
Page 10
Connecting the Inline Tester to a Charging Point and a Vehicle
The inline tester is equipped with a type 2 plug (7) for connection to the charging point. This can
be plugged into the charging point. The device is also equipped with a type 2 socket for connection
to the vehicle.
Diagnosis of the Charging Point and the Vehicle with the Inline Tester
Charging points can be tested in accordance with IEC 61851 with the help of the PROFITEST H+E
TECH inline tester in combination with an electric vehicle.
The device makes the following functions available:
Display of the Vehicle State (CP)
States A, B, C and D can be displayed 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 Display (PP)
The inline tester is equipped with a 20 A charging cable. The corresponding value (20 A) appears at
the display.
Display
Resistance
Max. Permissible Current
680 Ω
20 A
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Operating Instructions PROFITEST H+E TECH
Page 11
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
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 inline tester 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
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Operating Instructions PROFITEST H+E TECH
Page 12
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).
Operating the Inline Tester with the Rotary Switches
The rotary switches currently have no function (except for switching display illumination back on).
They’re included in order to be able to add menu driven operation by means of future product
updates.
Battery Display
Adequate battery voltage is imperative for testing the PWM signal. For this reason the inline tester
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 inline tester 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 inline tester 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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Operating Instructions PROFITEST H+E TECH
Page 13
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 3.65 kg
Protection IP 21
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Operating Instructions PROFITEST H+E TECH
Page 14
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 open 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 TECH
Page 15
Typical Pilot Electric Equivalent Circuit
for Mode 3 Charging
Typical pilot electric equivalent circuit
Source: IEC 61851
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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Operating Instructions PROFITEST H+E TECH
Page 16
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 TECH
Page 17
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
aApplicable 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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Operating Instructions PROFITEST H+E TECH
Page 18
System States – Duty Cycle
Table A.6 – Maximum Current to be Drawn by the Vehicle
Nominal duty cycle
interpretation by vehicle
Maximum current to be drawn by vehicle
Duty cycle < 3%
Charging not allowed
3% duty cycle 7%
A duty cycle of 5% indicates that digital communication is required
and must be established between the EVSE and EV before
charging.
Charging is not allowed without digital communication.
Digital communication may also be used with other duty cycles.
7% duty cycle 8%
Charging not allowed
8% duty cycle 10%
6 A
10% duty cycle 85%
available current = (% duty cycle) x 0.6 A
85% duty cycle 96%
available current = (% duty cycle - 64) x 2.5 A
96% duty cycle 97%
80 A
duty cycle > 97%
Charging not allowed
If the PWM signal is between 8% and 97%, the maximum current may not exceed the values
indicated by the PVM even if the digital signal indicates a higher current.
In 3-phase systems, the duty cycle value indicates the current limit per each phase.
The current indicated by the PWM signal shall not exceed the current cable capability and the
EVSE capability, the lower between them shall apply.
Note: the EV should respect 6A as lower value of the PWM.
Note: the indication "no maximum" implies that the delay time has no constraints and may
depend on external influences and the conditions existing on the EVSE or the EV.
Source: IEC 61851
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Operating Instructions PROFITEST H+E TECH
Page 19
System States – Duty Cycle
Diagnostics Unit for Testing Charging Points
Vehicle simulation
A charging point is more than just a simple electrical
outlet and it only functions when a vehicle is detected.
The diagnostics unit is capable of simulating a vehicle.
Diagnosis
The evaluation of the PWM signal, the cable coding for
the phases, turn-off times
and the direction of phase rotation are significant with
regard to diagnosis.
The diagnostics unit displays this information.
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