Phoenix Contact EV Charge Control Basic User manual

User manual
EV Charge Control Basic
Installing and starting up the
charging controller

2021-03-24
PHOENIX CONTACT GmbH & Co. KG • Flachsmarktstraße 8 • 32825 Blomberg • Germany
phoenixcontact.com
106377_en_05
EV Charge Control Basic
Installing and starting up the charging controller
This user manual is valid for:
Designation Version Order No.
EV-CC-AC1-M3-CBC-SER-HS
EV-CC-AC1-M3-CBC-SER-PCB
EV-CC-AC1-M3-CC-SER-HS
EV-CC-AC1-M3-CC-SER-PCB
4 1622452
1622453
1622459
1622460
User manual
UM EN EV-CC-AC1-M3-C, Revision 05

Table of contents
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Table of contents
1 Properties of the charging controller ..........................................................................................5
1.1 Ordering data ........................................................................................................ 6
1.2 Technical data....................................................................................................... 6
2 Connections, indicators, configuration switches ........................................................................9
2.1 Connections .......................................................................................................... 9
2.2 Diagnostic and status indicators.......................................................................... 11
2.3 Configuration switches S1 + S2........................................................................... 12
3 For your safety .........................................................................................................................15
3.1 Safety notes ........................................................................................................ 15
3.2 Maintenance and disposal................................................................................... 16
4 Startup .....................................................................................................................................17
4.1 Dimensions.......................................................................................................... 17
4.2 Mounting the PCB (EV-CC-...-PCB only)............................................................. 18
4.3 Mounting the housing (EV-CC-...-HS only).......................................................... 18
4.4 Mounting on the DIN rail ...................................................................................... 20
4.5 Connecting the supply voltage ............................................................................ 21
4.6 Connecting the charging contactor...................................................................... 21
4.7 Locking the Infrastructure Socket Outlet (EV-CC-...-CBC-... only)....................... 22
4.8 Configuration ....................................................................................................... 22
5 Signal contacts and charging sequences .................................................................................23
5.1 Proximity Plug (PP).............................................................................................. 23
5.2 Control Pilot signal (CP) ...................................................................................... 24
5.3 Charging cable connection (case B and C) ......................................................... 25
5.4 Vehicle status (status A - F)................................................................................. 26
5.5 Typical charging sequence.................................................................................. 27
5.6 Simplified charging sequence.............................................................................. 29
5.7 Activation mode................................................................................................... 30
6 Wiring the outputs and inputs ...................................................................................................31
6.1 Outputs................................................................................................................ 31
6.2 Inputs................................................................................................................... 33

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7 Connection examples ..............................................................................................................35
7.1 Charging enabled with local release.................................................................... 35
7.2 Charging enabled with local release and status indication via external LEDs...... 36
7.3 Charging enabled with local release and charging current reduction................... 37
7.4 Charging enabled with local release and locking................................................. 38
7.5 Charging enabled via Modbus............................................................................. 39
7.6 Charging current control via analog CCR signal .................................................. 40
7.7 Charging contactor monitoring ............................................................................ 42
7.8 Connection to a residual current monitoring device............................................. 44
8 Flow charts for the charging process .......................................................................................47
8.1 Charging sequence 1 .......................................................................................... 47
8.2 Charging sequence 2 .......................................................................................... 48
8.3 Charging sequence 3 .......................................................................................... 49
8.4 Charging sequence 4 .......................................................................................... 50
8.5 Charging sequence 5 .......................................................................................... 51
8.6 Charging sequence 6 .......................................................................................... 52
9 Modbus description .................................................................................................................53
9.1 Modbus register types ......................................................................................... 53
9.2 Register assignment............................................................................................ 54
9.3 Function assignment of output registers.............................................................. 63
A Appendixes...............................................................................................................................65
A 1 List of figures ....................................................................................................... 65

Properties of the charging controller
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1 Properties of the charging controller
The EV Charge Control Basic charging controller is exclusively used to control and monitor
the charging of electric vehicles on the 3-phase AC power grid in charging mode 3 accord-
ing to IEC 61851-1, AC level 2 according to SAE J1772, and mode 3 according to
GB/T 18487.1.
The charging controller is integrated in a defined charging infrastructure which is perma-
nently connected to the power grid.
The charging controller is designed to control the switching element which is used to estab-
lish the connection between the power grid and the electric vehicle. It has a communication
interface via which status data can be read and control signals can be written. The charging
controller monitors the Control Pilot and Proximity Plug signals.
The Control Pilot signal (CP) has the following functions, for example:
– Detection of the protective conductor connection
– Detection of the vehicle status: vehicle not connected, vehicle connected, vehicle
ready for charging, ventilation required, error
– Transmission of the charging controller status: ready, not ready, error
– Specification of the maximum available charging current for the vehicle via a PWM sig-
nal
The charging controller detects the inserted charging connector and the current carrying ca-
pacity of the charging connector and charging cable via the Proximity Plug signal (PP).
Resistor coding in the charging connector is used for this purpose.
The charging controller can be used to activate or deactivate the charging connector locking
in the charging station depending on the status.
As an option, the charging process can also be influenced and monitored via the existing
communication interface.
Technical features – Evaluating and controlling the Control Pilot signal
– Monitoring the connection to protective earth ground (PE)
– Evaluating the Proximity Plug signal
– Controlling the charging contactor and locking actuators
– Maximum charging current that can be configured: 16 A, 20 A, 32 A, 63 A
– RS-485 communication interface/Modbus/RTU (slave)
– Digital inputs and outputs, can be configured
– Controlling and enabling the charging controller locking in the event of a mains failure
– Temperature range: -35°C ... +70°C
– Altitude: < 2000 m
– Versions available for charging stations with an infrastructure socket outlet (connection
of case B) and vehicle connector (connection of case C)
– Available either as PCB or with housing for DIN rail mounting

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1.1 Ordering data
1.2 Technical data
Charging controller
Description Type Order No. Pcs. / Pkt.
Charging controller for connection of case B and C, with
housing for DIN rail mounting
EV-CC-AC1-M3-CBC-SER-
HS
1622452 1
Charging controller for connection of case B and C, as
PCB
EV-CC-AC1-M3-CBC-SER-
PCB
1622453 1
Charging controller for connection of case C, with housing
for DIN rail mounting
EV-CC-AC1-M3-CC-SER-
HS
1622459 1
Charging controller for connection of case C, as PCB EV-CC-AC1-M3-CC-SER-
PCB
1622460 1
Order number 1622452 1622453 1622459 1622460
EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB
Supply
Input voltage range 100 V AC ... 240 V AC
No-load power consumption < 1 W
Frequency range 50 Hz ... 60 Hz
RS-485 interface
Protocol Modbus/RTU (slave)
Transmission speed 9.6 kbps (default)
Can be set: 9.6 kbps or 19.2 kbps
Transmission mode
data bits / parity / stop bits 8 / N / 1
Relay output C1/C2
Switching capacity, maximum 1500 VA
Switching voltage, maximum 250 V AC
Switching current, maximum 6 A
Output, locking
Voltage 12 V DC 12 V DC – –
Current, maximum 2 A 2 A – –
Adjustable switching time 600 ms (default) 600 ms (default) – –
Digital output

Properties of the charging controller
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Voltage range, supply input
12Va 5 V ... 30 V
Maximum current per output 600 mA
Maximum total current with inter-
nal supply 500 mA
Digital input
Nominal input voltage 12 V
Nominal input current < 1 mA
Input voltage range 0 V … 3 V (OFF) / 9 V … 15 V (ON)
General data
Degree of protection IP20 IP00 IP20 IP00
Overvoltage category III (IEC 60664-1)
Pollution degree 2 (IEC 60664-1)
Ambient temperature
(operation) -35°C ... +70°C
Ambient temperature
(storage) -40°C ... +85°C
Humidity
(non-condensing) 30% ... 95%, non-condensing
Altitude < 2000 m
Dimensions W x H x D 124 mm x 128 mm
x 64 mm
120 mm x 108 mm
x 20 mm
124 mm x 128 mm
x 64 mm
120 mm x 108 mm
x 20 mm
Weight 275 g 140 g 260 g 125 g
Connection data
Connection method Screw connection
Nominal cross section 2.5 mm2
Conductor cross section, solid 0.2 mm2... 2.5 mm2
Conductor cross section,
stranded 0.2 mm2... 2.5 mm2
Stranded conductor cross
section with ferrule without plas-
tic sleeve
0.25 mm2... 1.5 mm2
Stranded conductor cross
section with ferrule with plastic
sleeve
0.25 mm2... 1.5 mm2
Conductor cross section
AWG/kcmil AWG 24 ... 14
Order number 1622452 1622453 1622459 1622460
EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB

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AWG according to UL/CUL AWG 30 ... 12
Conformance/approvals
CE-compliant √
Low-voltage directive 2006/95/EC
Safety test IEC 61010-1
Function test IEC 61851-1, Appendix A
Air clearances and creepage
distances IEC 61010-1
Order number 1622452 1622453 1622459 1622460
EV-CC-AC1-M3- CBC-SER-HS CBC-SER-PCB CC-SER-HS CC-SER-PCB
Conformance with EMC Directive 2004/108/EC and Low-Voltage Directive 2006/95/EC
Noise immunity test according to EN 61000-6-2
Protection for housing connections
Electrostatic discharge (ESD) EN 61000-4-2 Criterion B ±6 kV (contact discharge)
±8 kV (air discharge)
Electromagnetic HF field EN 61000-4-3 Criterion B 80 MHz ... 1 GHz, field strength 10 V/m, 80% AM
(1 kHz)
1 GHz ... 3 GHz, field strength 10 V/m, 80% AM
(1 kHz)
Protection for inputs and outputs, AC power connections
High frequency, asymmetrical EN 61000-4-6 Criterion A 150 kHz ... 80 MHz, 10 V, 80% AM (1 kHz)
Fast transients (burst) EN 61000-4-4 Criterion B ±2.2 kHz (peak)
5/50 ns (tr/tn)
5 kHz rep. frequency
Overvoltages EN 61000-4-5 Criterion B 1.2/50 ns (8/20) µs (tr/ th)
Up to ±1 kV, wire-to-wire
Up to ±2 kV, wire-to-ground
Voltage dip EN 61000-4-11 Criterion B
Criterion C
Criterion C
0% for one period
40% for 10/12 periods
70% for 25/30 periods
Voltage interruption EN 61000-4-11 Criterion C 0% for 250/350 periods
Protection for signal connections
High frequency, asymmetrical EN 61000-4-6 Criterion A 150 kHz ... 80 MHz, 10 V, 80% AM (1 kHz)
Fast transients (burst) EN 61000-4-4 Criterion B ±2.2 kHz (peak)
5/50 ns (tr/tn)
5 kHz rep. frequency
Overvoltages EN 61000-4-5 Criterion B 1.2/50 ns (8/20) µs (tr/ th)
Up to ±1 kV, wire-to-ground

Connections, indicators, configuration switches
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2 Connections, indicators, configuration switches
2.1 Connections
Figure 2-1 Connections
L
N
PE
GND
12V
12Va
EN
XR
ML
CCR
IN
OUT
ERR
CHG
CON
C1
C2
A
B
SG
CP
PP
LD1
LD2
L0+
L0-
IO
Relay
R 485S
Outlet
Power
PWR
S1 S2
CON
ERR
CHR
12
345
Table 2-1 Connections
No. Name Meaning Description
1LLine Phase, power grid 100 V AC ... 240 V AC (L-N)
NNeutral Neutral conductor, power grid
PE Protective Earth Functional earth ground, connected to protective earth ground
2GND Ground System ground, connected to protective earth ground
12V Power Output 12 V DC, max. 500 mA
12Va Auxiliary Power Supply input of the outputs 5 V DC ... 30 V DC
EN Enable Digital input, can be configured, enable charging process
XR External Re-
lease
Digital input, can be configured,
charging station availability
Activation via S1/DIP 2, can be configured
ML Manual Lock Digital input, can be configured,
manual locking
Activation via S1/DIP 3, can be configured
CCR Charge Current
Reduction
Digital input, charging current limit Depending on the default settings by
S1/DIP 5 + 6
IN Auxiliary Input Reserved for future expansions
OUT Auxiliary Out Digital output, can be configured Default: output can be set via Modbus *
ERR Error Digital output, can be configured Default: set when errors occur
Error or status E or status F
*
CHG Charging Digital output, can be configured Default: set when the charging contactor is
actuated
*
CON Connect Digital output, can be configured Default: set when a vehicle is connected to
the charging controller
*

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For further information on the configuration options for the digital inputs and outputs,
please refer to the “Modbus description” on page 53.
3LO- Locking Control of the locking actuator †
LO+
LD2 Lock Detection Digital input, for connecting the locking confirmation, can be configured †
LD1
PP Proximity Plug Test signal Current carrying capacity of the connected
charging connector and charging cable ac-
cording to
IEC 61851-1
†
CP Control Pilot Pilot wire signal Communication between charging station and
vehicle according to IEC 61851-1, SAE J1772
and GB/T 18487.1
4SG Signal Ground Ground signal for the RS-485 communication interface
BRS-485 Communication interface
A
5C2 Contactor Relay output, charging contactor Switches the mains voltage to the vehicle via an
external
charging contactor when status C or D is reached
and
the enabled inputs and registers are active.
C1
*Not protected against overload
†Not for EV-CC-AC1-M3-CC-...
Table 2-1 Connections [...]
No. Name Meaning Description

Connections, indicators, configuration switches
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2.2 Diagnostic and status indicators
Figure 2-2 Diagnostic and status indicators
Table 2-2 Diagnostic and status indicators
No. Name Meaning Color Status Description
6X1 Diagnos-
tics
Reserved for future expansions
PWR Power Green On Charging controller ready
Flashing
(1 Hz)
Charging controller is starting up
CON Connect Yellow On Charging cable is connected to the charging station and the vehicle
Flashing
(1 Hz)
Charging cable is connected to the charging station and locked
ERR Error Red On Error
Flashing
(1 Hz)
Errors that originate at the vehicle or charging cable
CHR Charging Blue On Charging contactor closed
Flashing
(1 Hz)
Vehicle connected, charging current ready, PWM signal switched
on, charging contactor open
L
N
PE
GND
12V
12Va
EN
XR
ML
CCR
IN
OUT
ERR
CHG
CON
C1
C2
A
B
SG
CP
PP
LD1
LD2
L0+
L0-
IO
Relay
R 485S
Outlet
Power
PWR
S1 S2
CON
ERR
CHR
6

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2.3 Configuration switches S1 + S2
WARNING: Dangerous contact voltage
Electrical shock from unprotected live parts.
Only set the configuration switches when the device is disconnected from the mains.
Figure 2-3 Configuration switches S1 + S2
L
N
PE
GND
12V
12Va
EN
XR
ML
CCR
IN
OUT
ERR
CHG
CON
C1
C2
A
B
SG
CP
PP
LD1
LD2
L0+
L0-
IO
Relay
R 485S
Outlet
Power
PWR
S1 S2
CON
ERR
CHR
S1 S2

Connections, indicators, configuration switches
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For additional information, please refer to “Flow charts for the charging process” on
page 47.
Table 2-3 Configuration switches S1 + S2
No. DIP Name Description
S1 1Connection,
case B/C
ON Charging station with vehicle connector (case C) *
OFF Charging station with infrastructure socket outlet (case B)
2XR evaluation ON XR input is evaluated, XR = 0 status F
OFF XR input is not evaluated or XR input is evaluated in a modified way according
to Modbus register 4011
3Locking function ON Connection locking upon signal at digital input ML, can be configured *
OFF Connection locking at status B
4Evaluation of
13 A charging
cable
ON 13 A charging cable is not permissible *
OFF 13 A charging cable is permissible
5+6 Default setting
for charging cur-
rent
Depending on digital
input CCR
CCR = 0 CCR = 1
5 = OFF 6 = OFF 16 A 8 A
5 = OFF 6 = ON 20 A 10 A
5 = ON 6 = OFF 32 A 13 A
5 = ON 6 = ON 63 A 20 A
7Evaluation of
Proximity Plug
ON Evaluation according to GB/T 18487.1 *
OFF Evaluation according to IEC 61851-1
8Optional
locking
ON No locking of the charging connector and evaluation of the locking confirma-
tion LD1/LD2
*
OFF Locking of the charging connector and evaluation of the locking confirma-
tion LD1/LD2
*
S2 1Baud rate ON 19200
OFF 9600
2-6 Modbus
address
ON = 1 0, 0, 0, 0, 1 = Modbus address 1
0, 0, 0, 1, 0 = Modbus address 2
…
1, 1, 1, 1, 0 = Modbus address 30
1, 1, 1, 1, 1 = reserved
OFF = 0
7+8 Reserved for future expansions
*Not for EV-CC-AC1-M3-CC-...

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For your safety
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3 For your safety
3.1 Safety notes
Startup only by specialist personnel
Installation, operation, and maintenance may only be carried out by qualified electricians.
Follow the installation instructions as described. When installing and operating charging
stations for electric vehicles, the applicable regulations and safety directives, as well as
general technical regulations, must be observed. The data on safety technology is provided
in this package slip and on the certificates, i.e., the conformity assessment and any further
approvals.
For additional information, please visit phoenixcontact.net/products.
Danger - hazardous contact voltages
The EV-CC-...-PCB printed-circuit board devices do not provide any protection against dan-
gerous contact voltage. With the EV-CC-...-HS DIN rail devices, parts with dangerous con-
tact voltage can be accessed after the covering hood has been removed.
Only install, remove, and configure the device when it is disconnected from the voltage. The
device may only be operated in a housing that corresponds to the currently applicable na-
tional requirements for charging stations.
Danger - mains voltage
On the EV-CC-...-PCB products, live parts are unprotected and can be accessed. When not
installed, protection against electrical shock is not provided. Only operate the device in a
closed housing that protects against electrical shock and corresponds to the applicable re-
quirements for charging stations.
Operation only in a suitable housing
The device may only be operated in a housing that corresponds to the requirements for
charging stations. Do not operate the device without a housing or in an inadequate housing.
Electrostatic discharge
The device contains components that can be damaged or destroyed by electrostatic dis-
charge. When handling the device, observe the necessary safety precautions against elec-
trostatic discharge (ESD) according to IEC 61340-5-1.
Observe these safety precautions, specifically for device EV-CC-...-PCB.

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Operation in a clean and dry environment only
The degree of protection of the device is designed for an environment with a maximum pol-
lution degree of 2 according to IEC 60664-1.
If the device is to be used for an outdoor charging infrastructure, one option for achieving
pollution degree 2 in the microenvironment is to provide a housing with IP5X protection ac-
cording to IEC 60529.
Do not subject the device to any strain or load that exceeds the limits described.
3.2 Maintenance and disposal
Maintenance With the exception of configuration, opening or modifying the device is not permitted. Do not
repair the device yourself; replace it with an equivalent device instead. Repairs may only be
carried out by the manufacturer.
Stop For stopping, the device must be disconnected from the mains voltage. Only remove the de-
vice when disconnected from the voltage.
Provide a disconnecting device for disconnecting the charging station from the voltage.
Disposal Do not dispose of the device with household waste, it should instead be disposed of in ac-
cordance with the currently applicable national regulations. The device can also be returned
to Phoenix Contact.
Product Degree of protection
EV-CC-...-PCB IP00 according to IEC 60529
EV-CC-...-HS IP20 according to IEC 60529

Startup
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4 Startup
WARNING: Dangerous contact voltage
Setup and startup may only be carried out by qualified personnel who are familiar with
the necessary safety precautions.
Observe the relevant requirements for setting up and starting up a charging infrastruc-
ture, and, in particular, the applicable safety regulations.
NOTE: Electrostatic discharge
The device contains components that can be damaged or destroyed by electrostatic
discharge. When handling the device, observe the necessary safety precautions
against electrostatic discharge (ESD) in accordance with IEC 61340-5-1.
4.1 Dimensions
Figure 4-1 Dimensions of EV-CC-...-PCB
Figure 4-2 Dimensions of EV-CC-...-HS
15
4,1
20,6
58
108
107
120
Ø4
124
128
64

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4.2 Mounting the PCB (EV-CC-...-PCB only)
WARNING: Dangerous contact voltage
Electrical shock from unprotected live parts.
Only mount the PCB when the device is disconnected from the mains.
Only operate the device in a charging station housing that corresponds to the applica-
ble requirements for charging stations.
For mounting the PCB, four bore holes (4 mm in diameter) are provided.
Ensure that there are sufficient air clearances and creepage distances from the conductive
surfaces.
4.3 Mounting the housing (EV-CC-...-HS only)
WARNING: Dangerous contact voltage
Electrical shock from unprotected live parts.
Only remove the covering hood when the device is disconnected from the mains.
Only operate the device in a charging station housing that corresponds to the applica-
ble requirements for charging stations.
Removing the covering hood
Figure 4-3 Removing the covering hood
The covering hood is not latched upon delivery. The covering hood must be removed in
order to configure the device.
• To remove the latched covering hood, lift the side panel. To do so, insert the tip of a
screwdriver into the lowest slot.
B
A

Startup
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Fitting the covering hood
Figure 4-4 Fitting the covering hood
Figure 4-5 Latching the covering hood
For assembly, proceed as follows:
1. Fit the covering hood so that it engages with a click.
2. To latch the lateral elements, push the four safety elements into the PCB.
Recommended tool: prong ø 3 mm
Ø3mm

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4.4 Mounting on the DIN rail
Figure 4-6 Mounting/removal
The device can be mounted in any position on the DIN rail.
Mounting on a DIN rail (A)
1. Place the device onto the DIN rail from above.
2. Push the front of the device toward the mounting surface until it engages with a click.
Removing from the DIN rail (B)
3. Push down the locking latch using a screwdriver, needle-nose pliers or similar.
4. Pull the bottom edge of the device slightly away from the mounting surface.
5. Pull the device diagonally upward from the DIN rail.
AB