LD Didactic 739 948 User manual

LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
09/19-W13-Wei
Instructions for use 739 948
Electric vehicle charging station
1Activate “Charging”
2Operating mode dis-
play
3Ready indicator
4System interface
MODBUS RTU
5Measuring sockets
5a CP signal (left)
5b PP/CC signal (right)
6Measuring sockets
L1 and N
7Main contactor indi-
cator
8Trip RCCB with
DC/AC switching and
knob
9
Charging socket
with hinged lid and in-
terlock
10 Schuko socket
230 V~
11 RJ45 connector
(Option!)
12 Fault switch
13 RCCB Type B
14 Triple fuse
(charging socket)
15 Fuses
single
16 Power supply con-
nection 3*400 V,
50/60 Hz
17 Connection auto-
motive high voltage
trainer,
739 947
Scope of delivery:
1 Electric vehicle charging station, 739 948
2 4 mm safety bridge connector orange
3 4 mm safety bridge connector black
1 CEE connection cable 400 V/16 A, 3 m
1 Instructions for use 739 948
0. Intended use
The “electric vehicle charging station” device is a teaching aid for
vehicle high-voltage technology training.
The device allows the trainee to perform typical workshop meas-
urements realistically.
Together with the automotive high voltage trainer, 739 947, the
device isused to createan electric vehicle charginginfrastructure
situation. A three-phase passive charging cable or a single-
phase active charging cable can be connected.

Instructions for use 739 948 Page 2/6
LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
Safety Information
Read these instructions for use completely before
1. Operation
1.0 Switch-on conditions
1. Make sure that all fault switches 12 are in the lower
position
1.1 Power supply
1. Plug the CEE socket of the supplied connection cable
into the right CEE socket 16 at the rear
2. a.) Switch fuses F1 and F2 (15) on (top position)
b.) Switch fuses F4- F6 (14) on (top position)
b.) Switch residual-current circuit breaker RCCB (13) on
(top position)
1.2 Connecting the automotive high voltage trainer,
739 947
1. Plug the CEE plug of the connection cable of the auto-
motive high voltage trainer, 739 947,into the left CEE
socket 17 into the back of the device
2. Plug the CEE plug of the connection cable of the auto-
motive high voltage trainer, 739 947,into the CEE
socket to the right of the Automotive high voltage
trainer, 739 947
3. Put the automotive high voltage trainer, 739 947 into
operation according to the instructions for use
commissioning and operating the device!
1.3 Connecting the three-phase charging cable
4. Plug the charging cable mode 3, 3~, 739 951, into the
charging socket 9on the charging station
5. Plug the charging cable mode 3, 3~, 739 951, into the
charging socket on the right side of the Automotive high
voltage trainer, 739 947
Fig. 1 - Charging socket on the automotive high voltage
trainer, 739 947
Failure to observe these operating instructions will void the
warranty/guarantee. No liability will be assumed for any con-
sequential damage!
No liability will be assumed for material damage or personal
injury resulting from improper handling or non-observance of
the safety information and the warranty/guarantee will expire
as a result!
•The device is only approved for use in dry indoor areas
that are installed in accordance with VDE 0100 Part 723!
•Operate and use only in accordance with DIN VDE 0105-112!
•The device must not be putinto operation if it exhibits vis-
ible signs of damage or behaves irregularly. If you are un-
sure, then do not put the device into operation! Have the
device immediately inspected by our service repair shop!
•The device may be used for training purposes only! The
device is not a toy and is not suitable for children!
•The device may only be used under the expert supervi-
sion of skilled and responsible personnel!
•Unauthorised modifications and/or changes to the device
are not permitted. The device may neither be opened nor
repaired!
•Measurements on all 4 mm measuring sockets may only
be made as described in the instructions for use. Applying
external voltages or generating high and low impedance
short circuits is expressly prohibited!
•Only the components described in these instructions for
use may be used on all 4 mm connection sockets!
•The device may only be used in conjunction with the auto-
motive high voltage trainer, 739 947 or the test adapter for
e-charging station, 739 953. Do not connect it to a real ve-
hicle!
•Exercise caution when handling the device. It can be dam-
aged by impacts, blows or from being dropped even from
a low height!
•Attention: the device is very heavy and may only be carried
by two persons!
•Only connect it to the mains using the supplied connection
cable!

Instructions for use 739 948 Page 3/6
LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
1.4 Charging
6. Activate the charging station by actuating enabling
switch 1
7. Activate the “charging” switch on the automotive high
voltage trainer, 739 947
8. The main contactor switches the charging voltage on
and blue indicator light 2lights up.
2. Application
2.1 CP communication signal
Communication with vehicle via the CP contact begins. The
charging current upper limit is transmitted to the vehicle by a
PWM signal. The protective earth conductor connection is
checked at the same time. A warning symbol or faulty installation
lights up when the protective earth conductor is missing.
The communication signal between the vehicle andcharging sta-
tion can be measured at the CP (5) socket against the PE socket
while charging.
Fig. 2 - Measuring sockets for the CP contact
The positive amplitude of the CP signal depends on the charging
status:
Status A«Active» Umax = +12 V
Status B«Ready» Umax ≈ +9.3 V
Status C«Charging» Umax ≈ +6.7 V, PWM active:
Fig. 3 - Status C, Charging
The coding resistance for the maximum permissible charging
current can be measured between the PP/CC and PEmeasuring
sockets. For charging cable mode 3, 3~, 739 951 that is 680 Ω,
which corresponds to 20 A.
Safety note
While charging is active, the plug is locked. Do not attempt
to forcibly pull out the plug since the locking mechanism
could otherwise be damaged!
In the delivery state, the charging request with Status D is re-
jected with an error message. This behaviour can be repro-
grammed via the MODBUS interface bysetting the 4010 address
(16 bit) from «0» (default) to «1».
Status D«Charging» Umax ≈ +3.4 V, PWM active:
Fig. 4 - Status D, charging with ventilation
The positions of the 4 mm measuring sockets of the CP and
PP/CC signals are selected so that a plug-in element can be in-
serted as a replacement directly against PE.
Insert an STE diode 578 51 as shown in order to ground the volt-
age of the CP signal and thus induce the «Status E» fault state.
This is indicated by an indicator light.

Instructions for use 739 947 Page 4/6
LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
Fig. 5 - Fault simulation of the CP contact
2.2 Checking the residual current circuit breaker
(“RCCB”)
RC can be tripped while charging. To do this, first activate fault
#F5 and set the potentiometer to the left stop. Subsequently use
switch 8to select whether you would like to induce an AC fault
current (top position)
or a DC fault current (bottom position). Since residual currentcir-
cuit breaker 13 must be a Type B model, residual DC currents
are detected as well.
Begin with an AC fault current (switch up). Slowly turn knob 8
clockwise to the right until the RCCB trips audibly. Keep the knob
in this position! Now switch to the “DC fault current” position
(switch down) and switch the residual current circuit breaker on
again. Keep turning the knob until the DC fault current trips the
residual current circuit breaker as well.
2.3 PP resistance
Insert an STE resistor as shown in order to simulate different cur-
rent carrying capacities of the charging cable as per IEC 61851.
Refer to the following table for the values.
Fig. 6 - Simulation of the current carrying capacity of the charging cable
Value [
Ω
] Current [A] Item number
100 63 577 32
220 32 577 36
680 20 577 42
1500 13 577 46
>2200 0 -
Table 1 - Coding resistances of the PP contact
Fig. 7 - 13 A
Fig. 8 - 20 A, duty cycle 33 % (33*0.6 A = 19.8 A≈20 A)
Fig. 9 - 32 A, duty cycle 53 % (53*0.6 A = 31.8 A≈32 A)
Fig. 10 - 63 A, duty cycle 89 % ([89-64]*2.5 A = 62.5 A≈63 A)

Instructions for use 739 948 Page 5/6
LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
The communication signals between the vehicle and charging
station can also be measured on the automotive high voltage
trainer, 739 947 at the intended 4 mm measuring socket for CP
against the PE socket while charging.
4 mm measuring sockets at the front of the device:
Fig. 11 - Measuring sockets on the automotive high voltage trainer, 739
947
Note
Even while charging, the PE socket of the charging socket is not
connected to the PE sockets of the automotive high voltage
trainer!
A “Status A” must follow after each change in resistance, other-
wise the new value is not loaded!
3. Fault switch
Fault Description
#F1 Return information Interlock Interruption
#F2 Control Interlock Interruption
#F3 PP signal Interruption
#F4 CP signal Interruption
#F5
Fault during residual current circuit breaker
test
Table 2 - Meaning of the fault switches
Several faults may be activated at the same time!
4. Modbus communication
4.1 Description
You can access the device’s registers via Modbus/RTU via
system interface 4. Modbus/RTU also allows you to make
additional configurations on the device, retrieve status in-
formation and control access to the charging process. The
device works as a Modbus slave; the address is perma-
nently set to 1. The baud rate is 9600 for communication.
You can find a detailed description of the register assign-
ment at the time this document was created here.
4.2 Establishing a connection
You need an RS485 interface (e.g. LEYBOLD
735 315USB), optionally a 9-pin serial standard connec-
tion cable as well communication software (everything not
included in the scope of delivery). You use the cable to
connect interface 4on the charging station to the RS485
interface of the computer. The 9-pin Sub-D socket is as-
signed as follows (without fixed 120 Ωterminating resis-
tor!):
Pin 8 A
Pin 3 B
4.3 Programming
Install and start the software according to the manufactur-
er's specifications. An Internet search for «Modbus TCP
RTU Master Software» provides useful results for free soft-
ware or for demo versions of programs offered commer-
cially.
Regardless which software you are using, you will need
the following information for input:
Mode: RTU
COM port: look in the Windows Device Manager
to see the port number under which the
interface you use was set up, here, for
example, number 7:
Fig. 12 - Determining the COM port number
Baud: 9600
Data bits: 8
Stop bits: 1
Parity: none
Slave ID: 1
CP
PP
PE

Instructions for use 739 947 Page 6/6
LEYBOLD DIDACTIC GMBH .Leyboldstrasse 1 .D-50354 Hürth, Germany .Phone [phone] .Fax [phone] .e-mail: info@leybold-
didactic.de
by Leybold Didactic GmbH Printed in the Federal Republic of Germany
Technical alterations reserved
Fig. 13 - Entering the interface parameters
If you want to read out «hardware revision», for example,
you will find a reference in the manufacturer information
that the hardware revision number is located in register
1030. The terms «address» and «register» are sometimes
used interchangeably.
In the program you also enter:
Address: 1030 (no offset or offset=0)

Value/data type: 16 bit (if necessary)
Function: 0x03 (read access)

Now start the requirement diagram with a «SEND» command or
similar

Fig. 14 - Reading out a register value
As a result, the charging controller returns the revision number
that is displayed in the software (in the example here, «5»).
Use this procedure to set register «4010» to «1», for ex-
ample, in order to allow vehicles with charging status «D»
(ventilation required) without error messages (see point
2.1).
5. Monitoring software
Follow the steps to establish a connection as described under
4.2. You can download at the time this document was cre-
ated the «EV CC Device Monitor» program from PHŒNIX
CONTACT in order to display various information directly and
make changes. Caution: improper handling can put the de-
vice in a state that no longer permits a factory reset!
Start the program, agree to the licence then enter the interface
parameters and click the button «Connect». Available parame-
ters will be shown automatically, changing parameters is simply
made by entering and confirming the new value.
o
6 Maintenance
The device does not require special maintenance. Only the test
button of residual current circuit breaker 13 must be pressed
every month.
7 Technical data
•Power supply: 3x400 VAC, 50 Hz, 16 A
•Connection CEE socket 400 V/16 A, 6h
•Output voltage: 3x400 VAC, 50 Hz, 2 A
•Connection CEE plug 400 V/16 A, 6h
•Charging socket: Type 2, 16 A
•Weight: approx. 25 kg
•Protection class 1
8 Disposal
Do not dispose of electric and electronic products
with normal household waste. Dispose of the un-
usable product in accordance with the applicable
statutory requirements.