Bender RCMB101 Bedienungsanleitung

Power in electrical safety

User Manual

RCMB101

CCID-20

AC/DC Ground Fault Current Module

for Electric Vehicle Charging Stations

Software version D359 V2

NAE1045320/11.2011

©Bender Inc.

Reprinting only with permission

of the publisher.

Subject to change!

Bender Inc.

USA:

700 Fox Chase

Coatesville, PA 19320

Toll Free: 1-800-356-4266

Phone: 610-383-9200

Fax: 610-383-7100

Canada:

5 Edvac Drive, Unit 14

Brampton, ON L6S 5P3

Toll Free: 800-243-2438

Phone: 905-799-0840

Fax: 905-799-3051

E-mail: [email protected]

Web: http://www.bender.org

Table of Contents

NAE1045320/09.2011

1. Safety Instructions .................................................................................................... 5

2. Function ....................................................................................................................7

2.1 Features ....................................................................................................................................... 7

2.2 Description ................................................................................................................................. 7

2.3 Function ...................................................................................................................................... 7

2.3.1 Self test after connection to the supply voltage .......................................................... 7

2.3.2 Cyclical self test ......................................................................................................................... 8

2.4 Analog voltage output X1 .................................................................................................... 8

2.5 Switching output X12 ............................................................................................................. 8

2.6 Control input X10 ..................................................................................................................... 9

2.6.1 Reset function ........................................................................................................................... 9

2.6.2 Reset and subsequent calibration of the RCMB101 ................................................. 10

2.6.3 Measuring sequence without charging electronics reset ...................................... 12

2.6.4 Verifying proper functionality of and testing X12 .................................................... 13

2.7 Starting sequence ................................................................................................................. 14

2.8 Values outside the permissible measuring range ..................................................... 16

2.9 Measuring range and switching times .......................................................................... 17

2.9.1 Measuring range ................................................................................................................... 17

2.9.2 Switching times without a contactor ............................................................................ 17

2.10 Fault detection and resulting reactions ........................................................................ 18

3. Installation and connection ............................................................................... 19

3.1 Installation ............................................................................................................................... 19

3.2 Terminal assignment ........................................................................................................... 19

3.2.1 Conductor routing through current transformer ...................................................... 20

3.3 Application examples .......................................................................................................... 20

3.3.1 Contactor is controlled by charger electronics and switching output signal . 20

3.3.2 Contactor is controlled by charger electronics .......................................................... 20

Table of Contents

4NAE1045320/09.2011

4. Technical data ....................................................................................................... 22

4.1 Data in tabular form .............................................................................................................. 22

4.2 Ordering information ........................................................................................................... 23

4.3 Approvals / Certifications ...................................................................................................23

4.4 Dimension diagrams ............................................................................................................ 24

NAE1045320 / 11.2011

1. Safety Instructions

Hazard of Electric Shock, Burn, or Explosion

Only qualified maintenance personnel shall operate or service this equipment. These instructions

should not be viewed as sufficient for those who are not otherwise qualified to operate or service this

equipment. This document is intended to provide accurate information only. No responsibility is as-

sumed by BENDER for any consequences arising from use of this document.

Turn OFF all sources of electrical power before performing any inspections, tests, or service on this

equipment. Assume all circuits are live until they have been properly de-energized, tested, ground-

ed, and tagged. Failure to observe these precautions will result in equipment damage, severe per-

sonal injury, or death.

Proper operation of this equipment depends on proper installation. Observe all relevant regulations,

code requirements, and standards when working on electrical installations. Neglecting fundamental

installation techniques will result in equipment damage, severe personal injury, or death.

Do not make any modifications to the equipment. Failure to observe this precaution will result in

equipment damage or personal injury.

Only use manufacturer’s and manufacturer recommended accessories with this equipment. Failure

to do so may damage the equipment beyond repair.

The RCMB101 is designed in compliance with the requirements described in UL 2231-2, "Standard

for personnel protection systems for electric vehicle (EV) supply circuits: Particular requirements for

protection devices for use in charging systems."

DANGER

Safety Instructions

6NAE1045320 / 11.2011

NAE1045320 / 11.2011

2. Function

2.1 Features

For use in level 1 and 2 AC electric vehicle charging systems

Detects both AC (0...500 Hz) and DC ground faults

Internal measuring current transformer with test winding and screening for electrical interfer-

ence field reduction, inside diameter 15 mm

Measuring range 0...20 mA, with analog voltage output

Switching signal at the output according to the requirements of UL 2231-2, type CCID20

Simple mounting of the module by snap-in locking mechanism at the current transformer

Monitoring of the connection to the measuring current transformer

Reset via control input X10

2.2 Description

The RCMB101 is a ground fault current module (CCID20) for monitoring AC/DC ground faults in elec-

tric vehicle charging stations. The CCID20 shall be mounted into the charging station as an open-

type circuit board. The electrical connection is made with circuit board plug connectors.

The AC/DC sensitive ground fault current module RCMB101 (alternate term CCID20) is suitable for

monitoring in electric vehicle charging stations where direct and/or alternating fault currents are

likely to occur with a value that is constantly greater than zero. This also applies to the detection of

leakage currents. The CCID20 is to be mounted into the charging stations as an open-type circuit

board. The electrical connection is established by means of circuit board plug connectors.

2.3 Function

The module detects the zero sequence current caused by leakage and fault currents in the conduc-

tors passed through the built-in current transformer. The module measures both AC and DC cur-

rents. The final value is calculated as an RMS value. A signal in proportion to the RMS value is made

available across the output X1. A second output marked X12 provides a switching signal when val-

ues are outside the permissible measuring range or in case of high or soaring ground fault currents.

2.3.1 Self test after connection to the supply voltage

Once the supply voltage has been switched on, the module carries out a two-stage self-test. In a first

sequence, a current flow of 11mA, 400Hz is applied to the test winding for one second. Then a direct

current of 22mA is applied, also for one second.

The resulting measured value of typical 1.2V of the first 11 mA test phase is available at the analog

output X1. The digital output X12 does not switch.

The 22 mA test phase causes the digital output X12 to switch after max. 800ms and makes an analog

output voltage of 4.85V available at X1.

The automatic start of calibration also causes the digital output X12 to switch.

Function

8NAE1045320 / 11.2011

2.3.2 Cyclical self test

Before each charging cycle, a reset with subsequent calibration has to be activated by the charging

control electronics via the input X10. This requirement can only be met when sufficient supply volt-

age +Us/- Us is available.

The ensuing sequence of measurements is described in "chapter 2.6.2". The automatic start of cali-

bration also causes the digital output X12 to switch. The cyclical self test is used to check the meas-

uring function of the device. This is a measure to ensure that the protective function is guaranteed.

2.4 Analog voltage output X1

The currently measured fault current is available at X1 as a proportional output voltage.

Output voltages < 150 mV or > 4.85 V not only signal a short-circuit or an interruption, but also a pos-

sible fault of the residual current monitoring module.

When a fault is recognised by the monitoring module, output X12 will simultaneously be switched

to the high-impedance state.

For details about fault detection, refer to page 17.

Values outside the measuring range >20 mA are also signalled via the switching output X12. In ad-

dition the analog output signal is provided at X1 for approx. 1.2 s and can be evaluated by the charg-

ers control electronics.

2.5 Switching output X12

Values outside the measuring range, a fault current of I20 mA or a fault detected by the monitor-

ing module are signaled by the Open Collector output X12. The switching output is in a high imped-

ance state.

Hysteresis: Only when the measured value of the residual current falls back below 10 mA, the tran-

sistor will open and the switching output X12 will be in the low-impedance state after 1.2 s.

In order to check the proper operation of the Open Collector output X12, a functional test according

to "chapter 2.6.2" can be initiated via the control input X10.

X12

Function

NAE1045320 / 11.2011

2.6 Control input X10

2.6.1 Reset function

A RESET of the RCMB101 can be carried out at any time via the control input X10.

NOTE: The ground fault current measurement is interrupted during this time.

For activating the RESET function, a LOW level is to be applied across the control input X10 for at least

T1 > 530 ms.

The ground fault current measurement remains active during the period T1. The ground fault cur-

rent measured at the time t2 remains stored until the residual current measurement is restarted after

applying a HIGH level at X10 for the period T3 > 5 ms.

X10

Enabling for measuring operation

Reset: End of residual current measurement

Currently measured value remains stored

> 0,53 s

X12

> 5 ms

Start of residual current measurement

Residual current

measurement inactive

HIGH

LOW

Function

10 NAE1045320 / 11.2011

2.6.2 Reset and subsequent calibration of the RCMB101

X10

Switching on the test current

in the test winding.

Reset: End of residual current measurement.

Currently measured residual current

remains stored.

> 0,53 s

X10=HIGH for 50 μs...100 μs

Reset and calibration

50...100 μs

X12

4,5 s

10...11 ms

Begin of calibration process

End of calibration process.

Start of residual current measurement.

HIGH

LOW

HIGH

0,1 s

0,15 s

0,85 s

> 5 ms

Measuring time for a change of

the residual current.

End of test current measurement and

switching off the test current.

Enabling for residual current

measurement.

Start of residual current measurement.

Begin of test current that causes a trip

1 s

Tripped in less than 700ms:

X12=high, X1 = 4,85V

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