Fluke FEV100 Bedienungsanleitung

FEV100

Electrical Vehicle Charging

Station Test Adapter

Users Manual

PN 5278136, April 2021

Specications are subject to change without notice.

All product names are trademarks of their respective companies.

Symbols

Symbol Description

WWARNING. RISK OF DANGER.

XWARNING. HAZARDOUS VOLTAGE. Risk of electric shock.

Consult user documentation.

TDouble Insulated.



Measurement Category II is applicable to test and measuring

circuits connected directly to utilization points (socket outlets

and similar points) of the low-voltage MAINS installation.

JEarth.

PE Protective Earth.

CP Control Pilot.

Vehicles not requiring ventilation for indoor charging areas.

Vehicles requiring ventilation for indoor charging areas.



This product complies with the WEEE Directive marking

requirements. The a󰀩xed label indicates that you must not

discard this electrical/electronic product in domestic household

waste. Product Category: With reference to the equipment

types in the WEEE Directive Annex I, this product is classed as

category 9 "Monitoring and Control Instrumentation" product.

Do not dispose of this product as unsorted municipal waste.

Table 1. Symbols

Introduction

The FEV100 (the Product) tests the function and safety of AC charging

stations Level 2 (208 V AC or 240 V AC) and Level 1 (120 V AC). With this

adapter, charging stations are tested in accordance with SAE J1772.

The adapter imitates a car and opens up a charging cycle (activate voltage/

current output). Use additional test and measurement equipment, such as

but not limited to: Multimeters, Clamps, Insulation testers or Multifunction

Testers, to test a charging station. In addition, the adapter has a built in quick

safety test that does not require separate equipment.

Contact Fluke

Fluke Corporation operates worldwide. For local contact information, go to

our website: www.uke.com

To register your product, view, print, or download the latest manual or manual

supplement, go to our website.

Fluke Corporation

P.O. Box 9090

Everett, WA 98206-9090

+1-425-446-5500

uke-info@uke.com

Safety Information

A Warning identies conditions and procedures that are dangerous to the

user. A Caution identies conditions and procedures that can cause damage

to the Product or the equipment under test.

WX Warning

To prevent the possibility of electric shock or personal injury:

• Read all safety information before you use the Product.

• Do not alter the Product and use only as specied, or the

protection supplied by the Product can be compromised.

• Carefully read all instructions.

• Do not touch voltages >30 V ac rms, 42 V ac peak, or 60 V dc.

• Before each use, examine the Product. Look for cracks or missing

pieces of the Product and cable assembly insulation. Also look for

loose or weakened components. Carefully examine the insulation

around the cable assembly connector.

• Only connect the Product to the charging stations as indicated in

the Specication section.

• Use the Product within the operating range only. The operating

range is specied in the Specication section.

• Do not touch any part of charging station during the GFCI test.

The GFCI test may place hazardous voltage onto conductive parts

of the charging station during the test if the charging station is

not properly grounded.

• Do not use the Product around explosive gas, vapor, or in damp

or wet environments.

• Do not apply more than the rated voltage, between the terminals

or between each terminal and earth ground.

• Use the correct terminals, function, and range for measurements.

• Do not use the Product if it operates incorrectly.

• Do not operate the Product with covers removed or the case

open. Hazardous voltage exposure is possible.

• Use only specied replacement parts.

• Do not use the Product if it is altered or damaged.

• Have an approved technician repair the Product.

Transport and Storage

Please keep the original packaging for future transport (for example if

calibration is necessary). Any transport damage due to faulty packaging will

be excluded from warranty claims.

The adapter must be stored in dry, closed areas. In case of the adapter being

transported in extreme temperatures, a minimum recovery time of 2 hours is

required prior to any operation.

Available Measurements

• Grounding system Pre-Test (veries that there is no presence of dangerous

voltage at the Ground terminal)

• Phase indicator (presence of voltage)

• CP State simulation (A, B, C , D ) for Control Pilot

• CP Error “E” simulation (Control Pilot CP signal short-circuited to PE)

• GFCI ground fault circuit interrupter test

• Fault Voltage test in normal conditions (no GFCI test current) and

during GFCI test

• PE Error (Earth Fault) simulation (interruption of PE conductor)

• Measurements on live conductors (L1, L2/N) and on PE ground

conductor

• Test of Control Pilot CP signal

Kit Components

The FLK-FEV100/TY1 Kit contains the following items:

1 FLK-FEV100/BASIC Test Adapter

1 FLK-FEV-COM/TY1 Type 1 Connector & Cable

1 Soft Carrying Case

1 Users Manual

Description of Warning Marks on Front Panel

1 Terminals with low voltage

output (approx. ±12 V) powered

by the charging station. Terminal

marked with Jis connected to

PE. Use for test purposes only.

The CP Signal Output terminals

can be hazardous if there is

a charging station error or

incorrect wiring.

2High danger of electric shock

is present when PE Pre-Test

indicator illuminates while

performing PE pre-test (see

Grounding protection Pre-Test).

In this case, stop testing

immediately. Make sure to

ground your body su󰀩ciently

while doing this test.

Figure 1. Front panel warning marks

3 Dangerous voltages can be present at L1, L2/N, and PE terminals while

the test adapter is plugged into the charging station. Use the test sockets

for test purposes only. Do not supply any appliance or charge an electric

vehicle via these connectors. Terminals N and PE can be hazardous if

there is a charging station error or incorrect wiring.

Operation Elements and Connectors

Figure 2. Front panel function

1CP Error “E” button

2Protective Grounding

test JPre-Test

warning indicator

3Protective Grounding

JPre-Test touch

probe

4Measurement

terminals L1, L2/N

5Voltage presence

indicator

6Measurement Ground

terminal

7Grounding error

simulation button

8GFCI test button and

green READY indicator

9CP State rotary

switch selector

(A, B, C , D )

10 Test cable input with 5-pole male connector

11 Test cable for specic EV charging station (Type 1 or Tesla)

1Test cable input

2CP Signal output terminal (yellow)

3CP Signal output terminal

(connected to PE) (green)

Figure 3. Top of the Product

123

Figure 4. Back of the Product

Testing Charging Stations

WX Warning

To prevent possible electric shock, re, or personal injury:

• Before starting any tests, the operator must be familiar with

the standard: SAE J1772, “SAE Electric Vehicle and Plug in

Hybrid Electric Vehicle Conductive Charge Coupler” and the

documentation of the charging station in use.

• Before starting any tests, refer to the local regulations and

standards for: safety at work and any relevant publications from

the Health and Safety Executive.

• Only skilled persons, competent in verication and the types of

tests suitable for installations and charging stations, should do

the tests.

• If the wrong types of tests are done or if testing is done in an

incorrect sequence then a potentially hazardous situation can

occur for both the operator and the DUT (Device Under Test).

• The operator must fully understand the various tests required and

how they should be done.

• The charging station must pass the Protective Earth (Ground) PE

Pre-Test prior to the operator touching exposed metal surfaces or

any other test. If the PE Pre-Test fails, stop further testing. Resolve

any faults before proceeding. In case of error, all metal parts of

the charging station including output terminals and PE can have

hazardous voltage. In this case, there is a high risk of electric

shock to the operator and other persons nearby.

• The PE Pre-Test detects the presence of hazardous voltage on

Protective Earth but may not detect an open Protective Earth.

Testing a charging station

To test the charging station:

1. Do a safety grounding protection pre-test (to verify that no dangerous

voltage is present in the grounding circuit due to possible miswire or

electrical wiring or grounding malfunction).

2. Verify station output voltage using an additional meter.

3. Verify station maximum preset charge current using CP terminals and

a meter with duty cycle function or an oscilloscope.

4. Simulate the error states as described in the SAE J1772 standard: CP

Error “E”, GFCI trip test, and Grounding Error.

Additional advanced tests such as Insulation Resistance, Power Quality,

Analysis of the Control Pilot waveform, and Loop Impedance can also be

done using the adapter in conjunction with appropriate test and measurement

equipment. The adapter is compatible with Fluke and Amprobe test and

measurement instrumentation.

Grounding protection Pre-Test

The Grounding J Pre-Test safety feature allows the operator to test the

PE conductor for possible presence of dangerous voltage against earth. In

normal circumstances, the grounding conductor is connected to earth and

therefore has no voltage against earth. However, if the grounding conductor

is not connected to earth (for example, connected to phase by mistake or the

grounding wire is disconnected or broken) the situation may be hazardous.

Operator skin contact is required on the PE PRE-TEST button (do not wear

gloves) as well as a suitable operator reference to a known earth ground

(through the operator's shoes etc.) Do not touch any metal parts of the

charging station while performing this test. In case of improper connection to

earth (for example, isolated placement of your body) this indication may be

not reliable.

WX Warning

The PE Pre-Test detects the presence of hazardous voltage on

Protective Earth but may not detect an open Protective Earth.

Test procedure:

1. Connect the test adapter to the charging station.

2. Touch the probe with a bare nger. If PE Light (item 2, Figure 2) is

illuminated, then dangerous voltage is present at ground conductor.

Stop further testing immediately and check for a possible wiring fault of

the tested ground conductor. In case of this error, the ground terminal

carries hazardous voltage. There is a high risk of electric shock.

Possible errors are:

• PE interrupted / not connected

• PE carries voltage (for example, connected to phase)

Verifying charging voltage - vehicle simulation

Use the CP State rotary switch selector, to simulate various vehicle states

when the test adapter is connected to the charging station. Vehicle states

are simulated with di󰀨erent resistances connected between CP and PE

conductors. Correlation between resistance and vehicle states is shown in

Table 2 below.

Marking

of Vehicle

State

Electric Vehicle (EV)

State

Resistance

between CP

and PE

Voltage at

CP terminal

A EV not connected Open (∞)±12 V

1 kHz

BEV connected, not ready

to charge 2.74 kΩ +9 V / -12 V

1 kHz

EV connected, ventilation

not required, ready to

charge

882 Ω +6 V / -12 V

1 kHz

DEV connected, ventilation

required, ready to charge 246 Ω +3 V / -12 V

1 kHz

Table 2. Correlation between resistance, vehicle state and CP voltage signal.

Initiating a charging cycle:

1. Connect the adapter cable to the charging station.

2. Turn a CP switch to B position and wait 3 to 5 seconds – in commercial

stations this may initiate a station to ask for payment information

3. Turn a CP switch to either C or D position depending on the type of

station you are testing (respectively with or without indoor charging

area ventilation requirement) to open the charging cycle.

Note

If the station does not begin the charging cycle, turn the CP switch

to position A. Then turn the CP switch to position B and wait 3 to

5 seconds. Then turn the CP switch to position C or D. Some EV

charging stations require a time delay to establish a proper connection

when CP State B is selected.

The red LED indicates that the charging station opened for the charging cycle

and voltage is present at the adapter terminals. The green READY indicator

should light up to indicate that the GFCI test circuit is ready for testing.

Measuring terminals of the adapter are directly connected to Phase 1 (L1),

Phase 2 (L2/N) or N (L2/N), and PE conductors of the charging station via

the test cable. Use these terminals for measuring purposes only. Do not use

the terminals to supply power to any other equipment.

Connect a meter to the L1 and L2/N terminals to perform output voltage

measurement. The terminals can be also used to perform other tests (for

example the loop impedance or Power Quality).

Verication of the charging station’s preset maximum charging current

and CP signal

The purpose of the CP function is communication between a vehicle and

charging station. The duty cycle of the PWM Pulse Width Modulation signal

denes the maximum available charging current.

CP output terminals are connected to CP and Ground conductors of the

charging station under test via the test cable. The green socket is connected to

Ground. These outputs are for connection of a meter with a duty cycle function

or an oscilloscope to check the waveform and amplitude of the CP signal.

For details of communication protocol refer to SAE J1772 and the

documentation of the manufacturer of the charging station.

Verication of the maximum charging current with a multimeter

Set a maximum charging current of the charging station using the internal

switch. The value of the maximum charging station current cannot exceed

the max current allowed by the gauge of the installed electrical wires and

breaker according to the National Electrical Code.

Testing maximum charging current:

1. Connect adapter to the charging station and select either state C or

D using rotary switch depending on the type of station to start the

charging cycle.

2. Connect meter set to Duty Cycle to the Control Pilot (CP) terminals

located on the top of the adapter. See Figure 3, use items 2and 3.

Make sure to connect COM input of the meter to the Green (Ground)

output of the CP terminal.

3. Read the duty cycle value and translate to maximum charging

current using the below formulas or a quick reference table (based on

J1772 standard).

Note

• Do not connect to L1, L2/N terminals.

• Connect the multimeter test leads after the charging station starts the

charging cycle. In some situations, the meter can inuence the CP

signal, and prevent the station from starting the charging cycle.

9.5 % ≤ Duty Cycle < 10 %, Maximum current = 6 A

10 % ≤ Duty Cycle ≤ 80 %, Maximum current = (duty cycle %) x 0.6

85 % < Duty Cycle ≤ 96 %, Maximum current = (duty cycle % - 64) x 2.5

96 % < Duty Cycle ≤ 96.5 %, Maximum current = 80 A

See detailed calculations in Table 3 below.

Duty Cycle (%) Max

Amps Duty Cycle (%) Max

Amps

9.5 6.0 40 24.0 70 42.0

10 6.0 41 24.6 71 42.6

11 6.6 42 25.2 72 43.2

12 7.2 43 25.8 73 43.8

13 7.8 44 26.4 74 44.4

14 8.4 45 27.0 75 45.0

15 9.0 46 27.6 76 45.6

16 9.6 47 28.2 77 46.2

17 10.2 48 28.8 78 46.8

18 10.8 49 29.4 79 47.4

19 11.4 50 30.0 80 48.0

20 12.0 51 30.6 81 48.6

21 12.6 52 31.2 82 49.2

22 13.2 53 31.8 83 49.8

23 13.8 54 32.4 84 50.4

24 14.4 55 33.0 85 51.0

25 15.0 56 33.6 86 55.0

26 15.6 57 34.2 87 57.5

27 16.2 58 34.8 88 60.0

28 16.8 59 35.4 89 62.5

29 17.4 60 36.0 90 65.0

30 18.0 61 36.6 91 67.5

31 18.6 62 37.2 92 70.0

32 19.2 63 37.8 93 72.5

33 19.8 64 38.4 94 75.0

34 20.4 65 39.0 95 77.5

35 21.0 66 39.6 96 80.0

36 21.6 67 40.2 96.5 80.0

37 22.2 68 40.8

38 22.8 69 41.4

Table 3. Calculations of max. charging current on basis of duty cycle.

Error states:

Duty Cycle = 0 % (Duty Cycle < 3 %), State F or E (see SAE J1772

Standard); no charging allowed

Duty Cycle = 5 % (4.5 % ≤ Duty Cycle ≤ 5.5 %), Indicates that digital

communication is needed

7 % < Duty Cycle < 8 %, Error state; no charging allowed

Duty Cycle = 100 %, State B1, C1 or D1; no charging allowed

CP Error “E” simulation

The standard SAE J1772 denes Error “E” as a state when charging station

is: disconnected from vehicle, disconnected from utility, there is a loss of

utility power or control pilot is short to control pilot reference (ground).

To simulate the CP Error “E”:

1. Push and hold CP Error “E”.

2. While holding the CP Error “E” button turn the CP rotary switch to

either C or D position.

3. The station should NOT open the charging cycle and a new charging

process should be prevented.

Note

The charging station is not required to actively generate the error

code, so the active charging process will not be interrupted if CP Error

“E” button is pushed after the charging cycle is initiated.

GFCI test

Each charging station is required to be equipped with GFCI protection. On

many stations the GFCI protection is fully automatic and does not need a

manual reset after the GFCI circuit is tripped.

Testing a GFCI protection:

1. Turn the CP switch to either C or D position depending on the type of

station you are testing (respectively with or without indoor charging

area ventilation required) to open the charging cycle.

2. The green READY indicator next to GFCI test button illuminates.

If the READY indicator blinks before you press the GFCI test button,

then fault voltage is higher than 45 V at the PE terminal. Check and

improve the grounding system before you do further tests.

WX Warning

Do not touch any part of charging station during the GFCI test.

The GFCI test may place hazardous voltage onto conductive parts

of the charging station during the test if the charging station is not

properly grounded.

3. Press the GFCI test button.

The station should terminate a charging cycle as soon as the GFCI

button is pressed.

If the READY indicator starts to blink after you press the GFCI test

button, then fault voltage during GFCI test was higher than 45 V. The

fault voltage was caused by the test current. Check and improve the

grounding system before you do further tests.

4. Unplug the adapter to reset the GFCI protection, if necessary.

Ground Error (Ground Fault) simulation

The Ground JError button simulates an interruption of the ground

conductor. As a result, the pending charging process is aborted, and new

charging processes are prevented.

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