Phoenix contact Ev-plcc-ac1-dc1 User manual

User manual

Installing and operating the

EV-PLCC-AC1-DC1 controller

2021-03-16

PHOENIX CONTACT GmbH & Co. KG • Flachsmarktstraße 8 • 32825 Blomberg • Germany

phoenixcontact.com

107068_en_06

Installing and operating the EV-PLCC-AC1-DC1 controller

UM EN EV-PLCC-AC1-DC1, Revision 06

Designation Order No.

EV-PLCC-AC1-DC1 1624130

User manual

This user manual is valid for:

107068_en_06 PHOENIX CONTACT 3 / 74

Table of contents

1 For your safety ...........................................................................................................................6

1.1 Identification of warning notes ............................................................................... 6

1.2 Qualification of users ............................................................................................. 7

1.3 Field of application of the product.......................................................................... 8

1.3.1 Intended use ..........................................................................................8

1.3.2 Foreseeable misuse ............................................................................... 8

1.3.3 Product changes .................................................................................... 8

1.4 Safety notes .......................................................................................................... 8

1.5 Information on installing and starting up charging stations for electric

vehicles ............................................................................................................... 10

2 Transport and unpacking .........................................................................................................11

2.1 Transport............................................................................................................. 11

2.2 Storage................................................................................................................ 11

2.3 Checking the delivery .......................................................................................... 11

2.4 Unpacking ........................................................................................................... 12

3 Description of the EV-PLCC-AC1-DC1 ....................................................................................13

3.1 General description of the controller.................................................................... 13

3.2 Hardware and software requirements.................................................................. 14

3.3 Connection and operating elements.................................................................... 15

3.4 Diagnostic and status indicators.......................................................................... 16

3.5 SD card ............................................................................................................... 20

3.6 Digital inputs........................................................................................................ 21

3.7 Digital outputs...................................................................................................... 23

3.8 Communication interfaces................................................................................... 25

3.8.1 Ethernet interfaces ............................................................................... 25

3.8.2 RS-232 interfaces ................................................................................ 26

3.8.3 RS-485 interfaces ................................................................................ 27

3.8.4 CAN bus interface ................................................................................ 29

3.8.5 Cellular modem .................................................................................... 31

3.9 Interfaces to the electric vehicle .......................................................................... 32

3.9.1 Interface for AC charging ..................................................................... 32

3.9.2 Interface for DC charging ..................................................................... 35

4 Mounting and connecting the hardware ...................................................................................39

4.1 Safety notes ....................................................................................................... 39

4.2 Basic information about mounting ....................................................................... 39

4.3 Mounting the controller........................................................................................ 40

4.4 Inserting the SIM card.......................................................................................... 40

4.5 Inserting the SD card........................................................................................... 40

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4.6 Connecting the conductors.................................................................................. 41

4.7 Connecting Ethernet............................................................................................ 42

4.8 Mounting and connecting the antenna................................................................. 42

4.9 Power supply of the controller ............................................................................. 43

4.9.1 Sizing of the power supply ................................................................... 43

4.9.2 Connecting the power supplies ............................................................ 44

4.9.3 Supply voltages ................................................................................... 45

4.9.4 Bridges ................................................................................................ 45

5 Signal contacts and charging sequences .................................................................................46

5.1 AC charging......................................................................................................... 46

5.1.1 Proximity Plug (PP) ..............................................................................46

5.1.2 Control Pilot (CP) ................................................................................. 47

5.1.3 Charging cable connection (case B and C) .......................................... 48

5.1.4 Typical charging sequence .................................................................. 49

5.2 DC charging ........................................................................................................ 51

5.2.1 Proximity Plug (PP) ..............................................................................52

5.2.2 Control Pilot (CP) ................................................................................. 52

5.2.3 Typical charging sequence .................................................................. 52

6 Function blocks for communication interfaces .........................................................................56

7 Removing the hardware ...........................................................................................................57

7.1 Safety notes .................................................................................................... 57

7.2 Removing the conductors.................................................................................... 57

7.3 Removing the controller....................................................................................... 58

7.4 Removing the SIM card ....................................................................................... 58

7.5 Removing the SD card......................................................................................... 59

8 After use ..................................................................................................................................60

8.1 Maintenance and servicing.................................................................................. 60

8.2 Device replacement............................................................................................. 60

8.3 Device defects and repair.................................................................................... 60

8.4 Disposal .............................................................................................................. 61

8.5 Return for disposal .............................................................................................. 61

9 Ordering data and technical data .............................................................................................62

9.1 Ordering data ..................................................................................................... 62

9.2 Technical data..................................................................................................... 63

9.3 Declaration of conformity in accordance with 2014/53/EU................................... 66

Table of contents

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A Appendix for document lists......................................................................................................67

A 1 List of figures ....................................................................................................... 67

A 2 List of tables ........................................................................................................ 70

A 3 Index.................................................................................................................... 71

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1 For your safety

Read this user manual carefully and keep it for future reference.

1.1 Identification of warning notes

This symbol indicates hazards that could lead to personal injury.

There are three signal words indicating the severity of a potential injury.

DANGER

Indicates a hazard with a high risk level. If this hazardous situation is not

avoided, it will result in death or serious injury.

WARNING

Indicates a hazard with a medium risk level. If this hazardous situation is not

avoided, it could result in death or serious injury.

CAUTION

Indicates a hazard with a low risk level. If this hazardous situation is not avoided,

it could result in minor or moderate injury.

This symbol together with the NOTE signal word warns the reader of actions

that might cause property damage or a malfunction.

Here you will find additional information or detailed sources of information.

For your safety

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1.2 Qualification of users

The use of products described in this user manual is oriented exclusively to:

– Electrically skilled persons or persons instructed by them. These users must be familiar

with:

– The detailed sequence of processes performed when charging electric vehicles

and the applicable safety concepts

– The professional setup and startup of charging stations for electric vehicles

– The safety concepts involved in automation engineering

– The applicable standards and other regulations, in particular

IEC 61851-1, -23, DIN SPEC 70121, CHAdeMO, and GB/T 27930

– Qualified application programmers and software engineers. These users must be famil-

iar with:

– The detailed sequence of processes performed when charging electric vehicles

and the applicable safety concepts

– The professional setup and startup of charging stations for electric vehicles

– The safety concepts involved in automation engineering

– The applicable standards and other regulations, in particular

IEC 61851-1, -23, DIN SPEC 70121, CHAdeMO, and GB/T 27930

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1.3 Field of application of the product

1.3.1 Intended use

The EV-PLCC-AC1-DC1 is a programmable controller which has been designed exclu-

sively for controlling charging stations for electric vehicles in accordance with IEC 61851-1,

-23, DIN SPEC 70121, CHAdeMO, and GB/T 27930.

The device has IP20 protection and is intended for use in charging stations for electric ve-

hicles.

1.3.2 Foreseeable misuse

The EV-PLCC-AC1-DC1 has been designed for stationary applications only. It is not suit-

able for use inside electric vehicles.

The EV-PLCC-AC1-DC1 is not suitable for general Powerline data communication via

Ethernet.

1.3.3 Product changes

Modifications to hardware and firmware of the device are not permitted.

Incorrect operation or modifications to the device can endanger your safety or damage the

device. Do not repair the device yourself. If the device is defective, please contact

Phoenix Contact.

1.4 Safety notes

Observe the country-specific installation, safety, and accident prevention regulations.

During startup and maintenance work, proceed in accordance with the five safety rules of

DIN EN 50110-1. In general, the rules should be observed in the order indicated below:

– Disconnect safely

– Ensure power cannot be switched on again

– Verify safe isolation from the supply

– Ground and short circuit

– Cover or safeguard adjacent live parts

Once the work is complete, perform the above steps again in reverse order.

NOTE:

The IP20 degree of protection (IEC 60529/EN 60529) requires that the device is used in

a clean and dry environment. Using the device in an environment that is outside of the

specified limits may cause damage to the device.

• Do not subject the device to mechanical and/or thermal stress that exceeds the spec-

ified limits.

For your safety

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NOTE: Risk of unauthorized network access

Connecting devices to a network via Ethernet always entails the risk of unauthorized ac-

cess to the network.

Therefore, please check for the option of disabling active communication channels in your

application (for instance SNMP, FTP, BootP, DCP, HTTP, HTTPS, etc.) or setting pass-

words to prevent third parties from accessing the controller without authorization and

modifying the system.

Due to its communication interfaces, the controller should not be used in safety-critical ap-

plications unless additional security appliances are used.

Please take additional precautions in accordance with the IT security requirements and

standards applicable to your application (e.g., virtual networks (VPN) for remote mainte-

nance access, firewalls, etc.) to prevent unauthorized network access.

On first request, you shall release Phoenix Contact and the companies associated with

Phoenix Contact GmbH & Co. KG, Flachsmarktstraße 8, 32825 Blomberg, Germany, in

accordance with §§ 15 ff AktG (German Stock Corporation Act), hereinafter collectively

referred to as “Phoenix Contact”, from all third-party claims made due to improper use.

For the protection of networks for remote maintenance via VPN, Phoenix Contact offers

the mGuard product range of security appliances, a description of which is provided in the

latest Phoenix Contact catalog (phoenixcontact.net/products).

Additional measures for protection against unauthorized network access are listed in the

AH EN INDUSTRIAL SECURITY application note. The application note can be down-

loaded at phoenixcontact.net/products.

NOTE: Electrostatic discharge

The device contains components that may be damaged or destroyed by electrostatic dis-

charge. When handling the device, observe the necessary safety precautions against

electrostatic discharge (ESD) in accordance with EN 61340-5-1 and IEC 61340-5-1.

NOTE: Device failure due to foreign objects in device

Foreign objects in the device can lead to malfunctions or even device failure.

• Ensure that no foreign objects find their way into the device (e.g., into the vents).

NOTE: Device failure if operated outside the permitted ambient temperature

range

Operating the device in ambient temperatures that are not within the permitted range may

lead to malfunctions or even device failure.

• Ensure that the device is operated within the permitted ambient temperature range,

see Section 9.2.

NOTE: Device failure due to vibrations and shock levels above the permitted

specifications during operation

If the device is subjected to vibrations and shock levels above the permitted specifications

during operation, this may lead to malfunctions or even device failure.

• Ensure that the permitted specifications for vibrations and shocks are adhered to

when operating the device, see Section 9.2.

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1.5 Information on installing and starting up charging

stations for electric vehicles

The majority of people using charging stations will not be experts. The charging voltages

and currents that are present, particularly the DC currents, can pose an increased safety

risk if they are used or programmed incorrectly.

• Ensure that you are familiar with the applicable standards and directives before install-

ing and starting up a charging station.

• Conduct a hazard and risk assessment for your charging station.

NOTE: Device defect due to polarity reversal

Polarity reversal puts strain on the electronics and can damage the device.

• To protect the device, avoid reversing the poles of the 24 V supply.

Transport and unpacking

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2 Transport and unpacking

2.1 Transport

The device is delivered in cardboard packaging.

• Only transport the device to its destination in its original packaging.

• Observe the instructions on how to handle the package, as well as the moisture, shock,

tilt, and temperature indicators on the packaging.

• Observe the humidity specifications and the temperature range specified for transport

(see Section 9.2).

• Protect the surfaces as necessary to prevent damage.

• When transporting the equipment or storing it temporarily, make sure that the surfaces

are protected from the elements and any external influences, and that they are kept dry

and clean.

2.2 Storage

The storage location must meet the following requirements:

– Dry

– Protected from unauthorized access

– Protected from harmful environmental influences such as UV light

– Temperature range: -40°C ... +85°C

– Air pressure: 70 kPa ... 106 kPa (up to 3000 m above sea level)

– Permissible humidity: 10% ... 95% (in accordance with DIN EN 61131-2)

2.3 Checking the delivery

• Check the delivery for transport damage.

Damaged packaging is an indicator of potential damage to the device that may have oc-

curred during transport. This could result in a malfunction.

• Submit claims for any transport damage immediately, and inform Phoenix Contact or

your supplier as well as the shipping company without delay.

• Enclose photos clearly documenting the damage to the packaging and/or delivery to-

gether with your claim.

• Immediately upon delivery, refer to the delivery note to ensure that the delivery is com-

plete.

• Keep the box and packaging material in case you need to return the product.

• We strongly recommend using the original packaging to return the product.

• If the original packaging is no longer available, observe the following points:

– Observe the humidity specifications and the temperature range specified for trans-

port (see Section 9.2).

– If necessary, use dehumidifying agents.

– Use suitable ESD packaging to protect components that are sensitive to electro-

static discharge.

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– Make sure that the packaging you select is large enough and sufficiently thick.

– Only use plastic bubble wrap sheets as the wadding.

– Attach warnings to the transport packaging so that they are clearly visible.

– Please ensure that the delivery note is placed inside the package if the package is

to be shipped domestically. However, if the package is being shipped internation-

ally, the delivery note must be placed inside a delivery note pocket and attached to

the outside so that it is clearly visible.

2.4 Unpacking

The EV-PLCC-AC1-DC1 is supplied in an ESD bag together with a packing slip with instal-

lation instructions.

• Read the complete packing slip carefully before unpacking the controller.

NOTE: Electrostatic discharge

The device contains components that may be damaged or destroyed by electrostatic dis-

charge. When handling the device, observe the necessary safety precautions against

electrostatic discharge (ESD) in accordance with EN 61340-5-1 and IEC 61340-5-1.

NOTE: Property damage due to non-compliance with ESD notes

If the ESD notes are not observed during unpacking and packaging, the device may be-

come damaged.

• Observe the ESD notes during unpacking and packaging.

Description of the EV-PLCC-AC1-DC1

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3 Description of the EV-PLCC-AC1-DC1

3.1 General description of the controller

The EV-PLCC-AC1-DC1 is a programmable controller for controlling charging stations for

electric vehicles.

IEC 61131 control perfor-

mance

The controller is fully configured and programmed in accordance with IEC 61131 using the

PC Worx automation software. PC Worx can be operated via the network (Ethernet). The

powerful processor can be programmed in all five IEC 61131 programming languages and

ensures quick control task processing.

Ethernet interfaces Two Ethernet interfaces are available. The Ethernet interfaces are switched internally.

RS-232 interfaces The controller features two RS-232 interfaces. Connections to peripheral devices can be

established via these interfaces.

RS-485 interfaces An RS-485 network of several peripheral devices can be established via the two RS-485 in-

terfaces.

CAN bus interface A CAN master interface is available for controlling CAN bus devices. Connections to several

peripheral devices can be established via this interface. In addition, the interface can be

used for communication between the charging station and electric vehicle in accordance

with CHAdeMO or GB/T 27930.

Interface for AC charging The controller features an interface for AC charging of an electric vehicle. The interface pro-

vides the following functions:

– Evaluation of signal contacts to the charging connector (Proximity Plug) and to the ve-

hicle (Control Pilot) in accordance with IEC 61851-1, Annex A

– Control of the charging connector locking and associated checkback contacts

– Input for connecting a Pt 1000 temperature sensor or a PTC chain for monitoring the

charging connector temperature

– Relay contact for connecting the charging contactor

Interface for DC charging The controller features an interface for DC charging of an electric vehicle. The interface pro-

vides the following functions:

– Evaluation of signal contacts to the charging connector (Proximity Plug) and to the ve-

hicle (Control Pilot)

– Communication between the charging station and electric vehicle in accordance with

DIN SPEC 70121

– Inputs for connecting two Pt 1000 temperature sensors for monitoring the charging con-

nector temperature

– Relay contact as a floating contact for charging enabled

SD card The SD-FLASH-2GB-EV-EMOB SD card (Order No. 1624092, see “Ordering data” on

page 62) is required to operate the controller. The SD card contains the license key for e-

mobility function block libraries. You can save programs and configurations belonging to

your project on the SD card.

Cellular networks Thanks to the integrated cellular modem, the controller can communicate with a backend

via OCPP over the cellular network.

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3.2 Hardware and software requirements

Table 3-1 Hardware and software requirements

Hardware/software Description

Charging controller EV-PLCC-AC1-DC1

Ethernet cable Ethernet cable for connecting the charging controller to

a PC

SD card For ordering data, see page 62

GSM/UMTS antenna For ordering data, see page 62

SIM card SIM card from a mobile network operator/provider to fa-

cilitate mobile communication for the charging controller

PC Worx ≥6.30.25191

1Included in AUTOMATIONWORX Software Suite 2019 version 1.86

E-Mobility Support Add-on for PC Worx2

2Can be downloaded at phoenixcontact.net/product/1624130

The associated quick start guide contains information on installing and using PC Worx.

The guide dan be downloaded at phoenixcontact.net/products and is also supplied with

the software.

Description of the EV-PLCC-AC1-DC1

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3.3 Connection and operating elements

Figure 3-1 Controller connection and operating elements

The controller consists of the following components:

1. X1: plug for 24 V supply voltage

2. X2.1/X2.2: Ethernet interfaces (RJ45)

3. X3: RS-232 interfaces

4. X4: RS-485 interfaces

5. X5: CAN bus interface

6. X6: plug for AC charging

7. X7: plug for relay output, charging contactor (AC charging)

8. X8: plug for DC charging

9. X9: plug for relay output, charging enabled (DC charging)

10. Antenna socket

11. SIM card holder

12. SD card holder

13. X10: plug for digital inputs

14. X11: plug for digital outputs

15. Diagnostic and status indicators

EV CHARGE CONTROL

Power

24 V

X1 X2.1 X2.2 X3 X4

RS232 RS485 CAN

COM

X6 X7

AC Charging DC Charging

X8 X9

SD ardC

Digital OUT X11Digital IN X10

SIMANT

RS232-1

RS232-2

RS485-1

RS485-2

CAN

GSM St.

GSM TR

Error

Plug

Charge

PLC

Error

Plug

Charge

DIAG

EV-PLCC-AC1-DC1

Ord. No. 1624130

CRTL COM EV

DCAC

X2.1 X2.2

10 11 12 13 14

675

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16 / 74 PHOENIX CONTACT 107068_en_06

3.4 Diagnostic and status indicators

Figure 3-2 Diagnostics and status indicators of the controller

X2.2 X3 X4

RS232 RS485 CAN

COM

X6 X7

AC Charging

SD ardC

Digital OUT X11Digital IN X10

RS232-1

RS232-2

RS485-1

RS485-2

CAN

GSM St.

GSM TR

Error

Plug

Charge

PLC

Error

Plug

Charge

DIAG

CRTL COM EV

DCAC

107068A012

Table 3-2 Diagnostics and status indicators of the controller

Des. Color Status Description

CTRL: controller diagnostics and supply voltage, and errors at digital outputs

UL Green

24 V supply, logic

Off Communications power not present.

On Communications power present.

UM Green

24 V supply, digital inputs

Off Voltage not present.

On Voltage present.

US Green

24 V supply, digital outputs

Off Voltage not present.

On Voltage present.

FR Green

Controller running

On IEC 61131 runtime system not ready to operate.

Flashing IEC 61131 runtime system successfully initialized.

Controller in READY/STOP state, program not being executed.

Off IEC 61131 runtime system successfully initialized and program running.

Controller in RUN state.

FF Yellow

Failure

Off No runtime error has occurred in the IEC 61131 runtime system program.

On A runtime error has occurred in the IEC 61131 runtime system program.

Description of the EV-PLCC-AC1-DC1

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ERed

Error

Off No short circuit/overload at one output/several outputs

On Short circuit/overload has occurred at one or more outputs 1 to 16.

COM: communication interfaces

RS232-1 Yellow

Communication via RS-232 interface 1

Off No data transmission