Megger EVCC 300 User manual

EVCC 300
Electric Vehicle Charger Checker
User Guide
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Declaration of Conformity
Hereby, Megger Instruments Limited declares that radio equipment manufactured by Megger Instruments Limited
described in this user guide is in compliance with Directive 2014/53/EU. Other equipment manufactured by Megger
Instruments Limited described in this user guide is in compliance with Directives 2014/30/EU and 2014/35/EU where they
apply.
This manual supersedes all previous issues of this manual. Please ensure that you are using the most recent issue of this
document. Destroy any copies that are of an older issue.
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Contents
1. Introduction 2
1.1 Product description ..................................................................................................................................2
1.2 Features.....................................................................................................................................................2
1.3 Applications ..............................................................................................................................................3
1.4 Company web site ....................................................................................................................................3
2. Safety Warnings 4
2.1 Warnings, Cautions and Notes ................................................................................................................4
2.1.1 Warnings ............................................................................................................................................... 4
2.1.2 Cautions ................................................................................................................................................ 4
2.1.3 Notes ..................................................................................................................................................... 4
2.2 Safety warnings ........................................................................................................................................4
2.3 Test lead safety warnings: .......................................................................................................................5
2.4 Installation category definitions:.............................................................................................................5
2.5 Safety, Hazard and Warning symbols on the instrument......................................................................6
3. Instrument Overview 7
3.1 Instrument layout.....................................................................................................................................7
3.2 Instrument display....................................................................................................................................8
3.3 Instrument softkey and test button controls..........................................................................................9
4. First use set up of the EVCC300 and setting 10
4.1 Turning the instrument on and off .........................................................................................................10
4.2 Battery options .........................................................................................................................................10
4.3 Settings .....................................................................................................................................................10
4.3.1 Direct or via cable charger connection setting......................................................................................... 10
4.3.2 Mains supply and touch voltage test settings.......................................................................................... 11
4.3.3 Language setting ................................................................................................................................... 11
5. Tests 12
5.1 Introduction..............................................................................................................................................12
5.1.1 Correct testing sequence........................................................................................................................ 12
5.2 Tests, PE (protective earth) touch pad test .............................................................................................13
5.2.1 Description............................................................................................................................................. 13
5.2.2 To perform the test ................................................................................................................................ 13
5.2.3 Interpreting test results........................................................................................................................... 14
5.3 Tests, RPE measurement ............................................................................................................................15
5.3.1 Description............................................................................................................................................. 15
5.3.2 How to perform the test ........................................................................................................................ 16
5.3.3 Interpreting test results........................................................................................................................... 17
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5.4 Tests, personal protection check..............................................................................................................19
5.4.1 Description............................................................................................................................................. 19
5.4.2 How to perform the test ........................................................................................................................ 20
5.4.3 Interpreting test results........................................................................................................................... 21
5.5 Nuisance trip check...................................................................................................................................24
5.5.1 Description............................................................................................................................................. 24
5.5.2 How to perform the test ........................................................................................................................ 24
5.5.3 Interpreting test results........................................................................................................................... 26
5.6 Tests, Proximitary check ...........................................................................................................................29
5.6.1 Description............................................................................................................................................. 29
5.6.2 How to perform the test ........................................................................................................................ 29
5.6.3 Interpreting test results........................................................................................................................... 29
5.7 Tests, Control pilot and charger output check .......................................................................................30
5.7.1 Description............................................................................................................................................. 30
5.7.2 How to perform the test ........................................................................................................................ 30
5.7.3 Interpreting test results........................................................................................................................... 32
5.8 Auto test sequence...................................................................................................................................33
5.8.1 Description............................................................................................................................................. 33
5.8.2 Test selection.......................................................................................................................................... 33
5.8.3 How to perform the test ........................................................................................................................ 33
5.8.4 Interpreting test results........................................................................................................................... 34
6. Error and Warning Conditions 35
6.1 On screen error messages ........................................................................................................................35
7. Settings 36
7.1 General settings........................................................................................................................................36
7.1.1 Description. ........................................................................................................................................... 36
7.1.2 Settings menu selection ......................................................................................................................... 36
8. Maintenance 38
8.1 General maintenance...............................................................................................................................38
8.2 Cleaning ....................................................................................................................................................38
8.3 Battery.......................................................................................................................................................38
8.3.1 Battery status ......................................................................................................................................... 38
8.4 Battery and fuse replacement .................................................................................................................39
9. Specifications 40
9.1 EVCC specifications ..................................................................................................................................40
9.2 Type 1 adaptor specifications..................................................................................................................43
10. Accessories and Equipment 44
10.1 Included accessories................................................................................................................................44
10.2 Optional accessories ...............................................................................................................................44
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11. Calibration, Repair and Warranty 45
11.1 Return procedure ...................................................................................................................................45
12. Decommissioning 46
12.1 WEEE Directive .......................................................................................................................................46
12.2 Battery disposal ......................................................................................................................................46
13. Notes 47
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1. Introduction
This user guide details the operational and functional details of the Megger EVCC300 Electric Vehicle Charger
Checker.
Please read this user guide fully before attempting to use the EVCC300.
1.1 Product description
The new EVCC300 represents a new concept in electric vehicle charger checking, providing a simple, all in one
solution. The name simply means: Electric Vehicle Charger Checker 300 = mode 3 chargers.
The compact, ergonomically designed instrument allows the user to quickly ensure a charger is in a safe, working
condition. This could be done prior to putting back into use following maintenance, or simply as a regular health
check to ensure everything is safe and working as it should be.
The EVCC300 is capable of checking both the safety and operation of a mode 2 and single-phase, mode 3 electric
vehicle charger and does it in a simple, easy-to-use manner.
One of the benefits of the new EVCC300 is that it not only sets control pilot conditions to allow other electrical tests
or to observe the charger’s reaction, it can also read the code received from the charger. The control pilot signal (CP)
is then compared with the requirements of IEC 61851-1:2017, without the need for a separate oscilloscope.
This makes the EVCC300 a unique solution to ensuring EV charger safety and reliability.
1.2 Features
The EVCC300 incorporates several grouped safety tests: protective earth integrity, nuisance tripping of an RCD or
GFCI, and connection communication and charging control, as follows:
1. Safety checking tests:
1.1. Protective Earth (PE) touch pad test: To detect faults such as open circuit ground connection, voltage present
on ground connection and other charger supply problems.
1.2. Protective conductor resistance measurement (RPE)
1.3. Touch voltage measurement (inherent part of any RCD / GFCI tests)
1.4. Personal protection check
RCD / GFCI trip time measurement
2. Nuisance tripping check test:
2.1. RCD / GFCI trip current measurement
3. EV charger operation checking tests:
3.1. Proximity pilot (PP) check
Indicate connection and latching
3.2. Control pilot (CP) check
Simulates electric vehicle (EV) control pilot (CP) states (A, B, C, D, E and F)
Reads back the set state from charger (CP voltage, duty cycle and frequency also displayed)
Displays charger maximum current available to car communication.
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1.3 Applications
The EVCC300 can check the safety and operation of single phase mode 3 chargers with type 2 connections and type
1 connections using an adaptor supplied as standard. The instrument is perfect for use in the following situations:
Following installation checking
Following repairs checking
Regular charger health checking
Manufacturing QA checking
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2. Safety
The safety instructions given in this document are indicative of safe practice and are not to be considered exhaustive.
Additionally, they are not intended to replace local safety procedures in the region where the instrument is used. If
the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
Apart from the battery and fuses within their respective handle and barrel compartments, there are no user
replaceable parts within the EVCC300. Do not open the case.
2.1 Warnings, Cautions and Notes
This user guide follows the internationally recognized definition of warnings, cautions and notes. These instructions
must be adhered to at all times.
2.1.1 Warnings
Warnings alert the reader to hazardous situations where injury to personnel can occur. They are set in red type to
make them stand out. They are placed before the item to which they relate and repeated at each applicable occasion.
2.1.2 Cautions
Cautions alert the reader to situations where equipment damage may result if a process is not followed properly.
They are set in bold type. They are placed before the item to which they relate and repeated at each applicable
occasion.
2.1.3 Notes
Notes give additional important information that will help the reader. They are not used when a Warning or Caution
is applicable. They are not safety related and may be placed either before or after the associated text as required.
2.2 Safety warnings
These safety warnings must be read and understood before the instrument is used. Retain for future reference.
Warning: This instrument must be operated only by suitably trained and competent people.
Protection provided by the instrument may be impaired if it is not used in a manner specified by the
manufacturer.
If this equipment is modified or used in a manner other than specified by the manufacturer, the protection
provided by the equipment may be impaired.
This equipment is not intrinsically safe and must not be used in hazardous atmospheres.
This equipment is for indoor and outdoor use up to 2,000 m altitude. It must not be used in wet conditions or
outside the specified temperature range.
Use only the adapters provided with the instrument.
If the equipment gets wet, turn off and disconnect, and wait for it to dry before turning back on.
Clean equipment with a dry, clean cloth.
Inspect the equipment for damage before each use. The equipment must not be used if any part of it is
damaged.
The touch-pad test must not be relied on to check protective earth integrity. It is an ‘open-circuit’ test and will
not indicate a high impedance earth connection.
A faulty protective earth connection to line may not be detected if the operator’s finger is not in contact with the
touch pad.
Voltage measurements are not continuous and therefore must not be relied upon for safety. The test button
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must be pressed to perform a one-time measurement. Use independent means to verify whether circuits are
energised. Safe working practices must be observed.
The PE (protective earth) pre-test must be carried out before any other test.
If the PE pre-test fail, there may be high voltage present within the charging station and on the output terminals
and a risk of electric shock. Other tests must not be started until the fault is investigated and rectified.
If no voltage is present between the L and N of the terminals or between the L and N of the test connector
when the instrument is connected to the charging point in charging mode, this may be because the instrument’s
internal fuse has blown.
Disconnect from all other equipment before opening the fuse or battery compartments.
Replacement fuses must be of the correct type and rating. Failure to fit the correctly rated fuse may result in a
safety hazard and may cause damage to the instrument in the event of an overload.
Use only non-rechargeable cells as specified in the instructions.
Replacement cells must be of the type specified in the instructions. Observe the correct polarity
No user serviceable parts are inside the equipment. Refer repairs to Megger approved service centres.
At the end of the equipment’s life dispose of it according to local regulations for recycling. Do not dispose of this
equipment to landfill.
2.3 Test lead warnings:
Test leads, including crocodile clips, must be in good condition, clean, dry and free of broken or cracked
insulation. The lead set or its components must not be used if any part of it is damaged.
2.4 Measurement categories:
CAT IV - Measurement category IV: Equipment connected between the origin of the low-voltage mains supply and
distribution panel.
CAT III -Measurement category III: Equipment connected between the distribution panel and electrical outlets.
CAT II - Measurement category II: Equipment connected between the electrical outlets and user’s equipment.
Measurement equipment may be safely connected to circuits at the marked rating or lower. The connection rating is
that of the lowest rated component in the measurement circuit.
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2.5 Safety, Hazard and Warning symbols on the instrument
This paragraph details the various safety and hazard icons on the instrument’s outer case.
Icon Description
FWarning: HIGH VOLTAGE, Risk of electric shock
GCaution: Refer to user guide.
Equipment complies with current UK legislation
cEU conformity. Equipment complies with current EU directives.
Equipment complies with current ‘C tick’ requirements.
Do not dispose of this equipment to landfill.
tDOUBLE INSULATED. This instrument has double or reinforced insulation throughout.
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3. Instrument Overview
3.1 Instrument layout
1 4 5 6 7 1
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Item Description Item Description
1 Type 2 EV male connector 6 Test button
2 Touch voltage / PE (protective earth) test
touch pad
7 Fuse compartment
3 ON / OFF button 8 4 mm socket ground / earth bond lead
connection
4 Display 9 Battery compartment
5 Softkeys
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3.2 Instrument display
The EVCC300 display is a 320x240 colour TFT screen.
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Item Description Item Description
1 Screen title 5 Softkey 2 function
2 Main display area 6 Softkey 3 function
3 Supply and touch voltage settings 7 Battery condition indicator
4 Softkey 1 function 8 Charger connection setting indicator
The purpose of the main display area is to show the measurement results. The information shown in the main display
area and the way it is arranged depends on the test you are carrying out and is explained in the relevant sections for
each type of test.
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3.3 Instrument softkey and test button controls
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1 3
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Item Description Item Description
1 Softkey 1 and ON / OFF button 4 PE touch pad
2 Softkey 2 5 TEST button
3 Softkey 3
The softkey bar at the bottom of the screen shows the functions of the softkeys. The function of each key is
shown immediately above the key itself. This function will change according to the mode selected.
Softkey 1 is also the ON / OFF button.
To turn the instrument ON press this button.
To turn the instrument OFF, press and hold down this button for a short period. When released the instrument
will turn OFF.
TEST button - To prevent accidentally starting a test the user must hold this button down for a short period to
start the test.
Where SELECT appears the button needs to pressed momentarily to select that test or function.
Where BACK appears in blue, the button needs to be pressed and held for a longer period to operate moving
back to the previous screen. The blue is to remind the user that a long press is required to operate.
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4. First use set up of the EVCC300 and setting
4.1 Turning the instrument on and off
1. To turn the EVCC300 ON press and hold softkey (1).
2. To turn the EVCC300 OFF press and hold softkey (1).
Before use it is important that the EVCC300 is set up correctly. The following the appropriate supply settings.
There are four options as follows:
1. 230 V, 1 Ph (EU / UK)
2. 120 V, 1 Ph (US)
3. 208 V, 2 Ph (US)
4. 240 V, 2 Ph (US)
Once the initial supply settings have been set the settings will be accessed in the order shown below in section c.
4.2 Battery options
The EVCC300 operates from four alkaline AA battery cells.
Warning: DO NOT use rechargeable batteries in the EVCC300
4.3 Settings
4.3.1 Direct or via cable charger connection setting
The EVCC has the capability to detect and test the proximity and latched status of the connection to the charger. To
be able to achieve this the instrument will need to know whether it is plugged into a charger directly or via a tethered
or connection cable.
When selecting settings the EVCC300 will allow the user to toggle between charger connection method:
1. Press softkey 1 or 3 (arrows) to highlight the desired setting
2. Press softkey 2 to SELECT. When the required connection
method is selected the EVCC300 will immediately return to
the main menu screen.
or
3. Select softkey 3 (NEXT) to advance to the next setting screen,
Supply Settings.
This will allow a rapid change of connection method while
testing. In the main menu screen there is an indicator in the top
left of the screen.
In this example of a menu screen the EVCC300 is set to direct
connection. If the red cross is not present the instrument is set
for connection to the charger via a tethered cable or plug in
charging cable.
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First use set up of the EVCC300 and setting
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4.3.2 Mains supply and touch voltage test settings
User preferred voltage options can be selected from here. Selected voltages will be saved and shown on screen in the
grey ribbon at all times. These voltages can be changed at a later time if required.
1. Press softkey 1 or 3 (arrows) to highlight the desired setting
2. Press softkey 2 to SELECT. When the required supply setting
is selected the EVCC300 will immediately return to the main
menu screen.
or
3. Select softkey 3 (NEXT) to advance to the next setting screen,
Language Settings.
4.3.3 Language setting
1. Press softkey 1 or 3 (arrows) to highlight the desired setting
2. Press softkey 2 to SELECT.
When the required supply setting is selected the EVCC300 will
immediately return to the main menu screen.
These settings can be changes at any time. Refer to 6. Settings on page 36
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First use set up of the EVCC300 and setting
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5. Tests
5.1 Introduction
5.1.1 Correct testing sequence
The EVCC300 incorporates effectively four safety tests (1.1 to 1.4 in the list below), one test to determine if nuisance
tripping of an RCD or GFCI is likely to occur (2.1 in the list below) and two operational (charger output enabled) tests
(3.1 to 3.2 in the list below) :
Warning: It is important for safety reasons to apply these tests in the order shown below:
1. Safety checking tests:
1.1. Protective Earth (PE) touch pad test: This test can indicate a number of faults:
Charger is not earthed / grounded
Charger earth / ground has live voltage present
Charger is not able to output a charging voltage
1.2. Protective conductor resistance measurement (RPE)
1.3. Touch voltage measurement (inherent part of any RCD / GFCI tests)
1.4. Personal protection check
RCD / GFCI trip time measurement
This includes the DC current trip time as this is essential to ensure the AC current element of the
protection remains functioning.
2. Nuisance tripping check test:
2.1. RCD / GFCI trip current measurement
3. EV charger operation checking tests:
3.1. Proximity pilot (PP) check
3.2. Control pilot (CP) check
Simulates electric vehicle (EV) control pilot (CP) states (A, B, C, D, E and F)
Reads back the set state from charger (CP voltage, duty cycle and frequency)
Displays the current available being communicated to the car
Warning: This sequence is important because it ensures the charger is safe before performing the
operational tests in the charger.
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5.2 Tests, PE (protective earth) touch pad test
5.2.1 Description
This is the first test that should be performed when using the EVCC300 to test a mode 2 or 3 vehicle charger.
During this test the charger is quickly powered up. If there is a ground / earth connection present the instrument will
indicate PROCEED. Should there be no ground / earth connection to the charger, or a voltage present on the ground
/ earth the test will indicate FAULT. This test is done by using a touch pad, in conjunction with a series of voltage
measurements.
Fig 1: Pass screen Fail screen
NOTE: This test is disabled when the mains supply is set to 240 V 2 Ph US. This is because this test will not work on
2 phase 180° supply.
WARNING: The PE contact / touch-pad test is not a bonding test and must not be relied on to check
protective earth integrity. It is an ‘open-circuit’ detect test and will not indicate a high impedance earth
connection.
5.2.2 To perform the test
1. Switch the instrument ON.
2. Ensure the mains supply to the charger is powered up and on.
3. Plug the EVCC300 into the charger outlet, either directly into
a type 2 connector or using the adaptor provided into a type
1 connector.
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Ensure the connection method indicated in the top left corner of
the MENU screen is correct.
As a reminder the menu screen connection indicator looks like
this.
In this screen the EVCC300 is set to direct connection. If the red
cross is not present the instrument is set for connection to the
charger via a tethered cable or plug in charging cable.
4. Use the softkeys 1 and 3 (Left and right) to select the “PE
contact” test indicated in black.
5. Press softkey 2 to SELECT the test.
6. Firmly press a finger on the PE contact pad.
7. Press and hold the TEST button while keeping a finger on the
contact pad.
During the test the EVCC300 will apply a charging code to the charger to put it into the charging state. This
is to allow the PE contact test to detect if a ground or earth connection is not present. The EVCC300 will then
measure the voltages between L to N, L to PE and N to PE (referring to the plug connections) to ensure the
voltages correct before progressing to the PE touch pad test. The test conditions for the voltage may be found
in the specification section of this manual.
5.2.3 Interpreting test results
The EVCC300 uses input voltage measurements as well as touch pad to detect EV charger’s PE wiring irregularity.
Hence it is essential for users to place fingers on touch pad when instructed on EVCC300’s screen during each PE test
in order to avoid inaccurate test outcome.
When incorrect wiring causes PE to be live such as shown below:
EV charger’s L -> L
EV charger’s N -> N
EV charger’s PE -> L
The EVCC300 will not detect this fault unless the user’s finger is on the pad.
When an EV charger’s Earth is open-circuit such as shown below:
EV charger’s L -> L
EV charger’s N -> N
EV charger’s PE -> Open-circuit ( >600 kΩ)
The EVCC300 will detect this fault
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When an EV charger’s Earth is incorrectly wired to main neutral such as shown below:
EV charger’s L -> L
EV charger’s N -> N
EV charger’s PE -> N
Neither the voltage measurements nor the touch pad with detect such fault.
Failure to follow test instructions on screen may result in hazardous PE wiring undetected.
These conditions are applicable to UK 230 V, US 120V 1 Ph and US 208 V 2 ph.
If the EVCC300 has not detected a problem the instrument will indicate PROCEED. This means it is OK to
proceed to the next tests
If the EVCC300 detects a problem the instrument will indicate FAULT
Should this occur do not proceed with further testing. The charger should be isolated from the mains supply and a
qualified electrician consulted.
The fault could be caused by a number of issues, but they can be summarised as being in one of these three
categories:
Charger is not earthed / grounded
Charger earth / ground connection has a live voltage present
Charger is not able to output a charging voltage. The EVCC300 will apply a C code to enable charging during
the test.
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5.3 Tests, RPE measurement
5.3.1 Description
The second test to perform is the RPE test. In this test a continuity test is performed between the ground / earth pin on
the charger socket and the 4 mm socket on the bottom of the instruments handle. This test is used on chargers that
have exposed metalwork to check it is connected to the ground / earth pin on the charging socket / plug.
Fig 2: Pass screen Fail screen
NOTE: If there is no exposed metalwork on the charger or the charger is marked with the double insulation symbol
this test is not required.
WARNING: Ensure a PE touch test to check the integrity of the EVSE PE terminal before conducting the
RPE test.
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