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electric vehicle charging pcb assembly inspection checklist

Quick start guide UM EN EV-SET-T2AC-BAS-RCM1-20AC5MES

Quick start guide

EV-SET-T2AC-BAS-RCM1-20AC5MES HOME charging technology set with AC charging cable

UM EN EV-SET-T2AC-BAS-RCM1-20AC5MES

2017-05-11 PHOENIX CONTACT 107839_en_00 EV-SET-T2AC-BAS-RCM1-20AC5MES HOME charging technology set with AC charging cable

UM EN EV-SET-T2AC-BAS-RCM1-20AC5MES 00

DesignationVersionOrder No.
EV-SET-T2AC-BAS-RCM1-20AC5MES001628077

Quick start guide

Designation: Version: This quick start guide is valid for: PHOENIX CONTACT Please observe the following notes

User group of this manual

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

  • Qualified electricians or persons instructed by them, who are familiar with applicable standards and other regulations regarding electrical engineering and, in particular, the relevant safety concepts.
  • Qualified application programmers and software engineers, who are familiar with the safety concepts of automation technology and applicable standards.

Explanation of symbols used and signal words How to contact us Internet

Up-to-date information on Phoenix Contact products and our Terms and Conditions can be found on the Internet at: phoenixcontact.com Make sure you always use the latest documentation. It can be downloaded at: phoenixcontact.net/products

Subsidiaries

If there are any problems that cannot be solved using the documentation, please contact your Phoenix Contact subsidiary. Subsidiary contact information is available at phoenixcontact.com.

Published by PHOENIX CONTACT GmbH & Co. KG Flachsmarktstraße 8 32825 Blomberg GERMANY Should you have any suggestions or recommendations for improvement of the contents and layout of our manuals, please send your comments to: pcb@frankenthalerfoundation.org This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety measures that follow this symbol to avoid possible injury or death. There are three different categories of personal injury that are indicated with a signal word.

DANGER

This indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

This indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. This symbol together with the signal word NOTE and the accompanying text alert the reader to a situation which may cause damage or malfunction to the device, hardware/software, or surrounding property. This symbol and the accompanying text provide the reader with additional information or refer to detailed sources of information. PHOENIX CONTACT

General terms and conditions of use for technical documentation

Phoenix Contact reserves the right to alter, correct, and/or improve the technical documentation and the products described in the technical documentation at its own discretion and without giving prior notice, insofar as this is reasonable for the user. The same applies to any technical changes that serve the purpose of technical progress. The receipt of technical documentation (in particular user documentation) does not constitute any further duty on the part of Phoenix Contact to furnish information on modifications to products and/or technical documentation. You are responsible to verify the suitability and intended use of the products in your specific application, in particular with regard to observing the applicable standards and regulations. All information made available in the technical data is supplied without any accompanying guarantee, whether expressly mentioned, implied or tacitly assumed. In general, the provisions of the current standard Terms and Conditions of Phoenix Contact apply exclusively, in particular as concerns any warranty liability. This manual, including all illustrations contained herein, is copyright protected. Any changes to the contents or the publication of extracts of this document is prohibited. Phoenix Contact reserves the right to register its own intellectual property rights for the product identifications of Phoenix Contact products that are used here. Registration of such intellectual property rights by third parties is prohibited. Other product identifications may be afforded legal protection, even where they may not be indicated as such. 107839_en_00 PHOENIX CONTACT 5

Table of contents

SectionTitlePage
1Intended use7
2General safety notes8
3Transport9
4Scope of supply10
5Additional accessories to be provided11
6Technical data12
6.1AC charging controller12
6.2Residual current monitoring device13
6.3AC charging cable14
6.4Park position15
7Dimensions16
7.1Park position16
7.2Vehicle Connector of the charging cable16
8Mounting17
8.1Space limits17
8.2Before mounting17
8.3Wiring example17
8.4Mounting the charging technology set18
8.5Mounting the park position19
8.6Checking the assembly19
9Installation and startup20
9.1Preparing cables and lines21
9.2Starting up the charging technology set22
9.3Configuring the AC charging controller24
9.4Detailed information on the configuration26
10Operation27
11Maintenance29
11.1Maintenance interval29
11.2In the case of defects29
11.3Documenting maintenance29
EV-SET-T2AC-BAS-RCM1-20AC5MES6 PHOENIX CONTACT 107839_en_00
11.4Diagnostics and status indicators30
11.4.1AC charging controller30
11.4.2Residual current monitoring device30
11.5Maintenance and cleaning with the power supply disconnected31
11.6Troubleshooting33
12Dismantling, decommissioning, disposal33
12.1Dismantling33
12.2Decommissioning and disposal34
13Storage34

Intended use

107839_en_00 PHOENIX CONTACT 71 Intended use

The HOME charging technology set is designed for assembling a charging station for elec-trically driven vehicles (electric cars). It consists of the following components:

  • AC charging cable with Vehicle Connector, protective cap, and open cable end
  • Park position/holder
  • EV Charge Control Basic AC charging controller
  • 1-channel residual current monitoring device (RCM)
  • Accessory kit with connection accessories
  • Documentation (circuit diagram, this instruction manual, documentation on the individ-ual components)

Additionally required components are to be provided by the customer and can be removed, see Section 5. Only operate the charging technology set in accordance with the information in this instruc-tion manual. Do not make any changes, additions or alterations to the charging technology set which are not described in this document. The use of third-party products and compo-nents must be recommended and/or approved by Phoenix Contact. Third-party products must be installed in accordance with the associated technical documentation. The safety risks posed by the charging technology set must be verified and assessed following the in-stallation of third-party products in the existing system/in the plant. Error-free and safe op-eration of the charging technology set can only be ensured through correct

  • Transport,
  • Storage,
  • Mounting/setup,
  • Installation,
  • Startup,
  • Operation and
  • Maintenance

Observe the permissible ambient conditions. At regular intervals, check the charging technology set according to the respective applica-ble national regulations, e.g.,

  • “DGUV regulation 3 and 4 – electrical installations and equipment”
  • German Ordinance on Industrial Safety and Health in association with TRBS 1201 and TRBS 1203
  • “Electrical systems for electric road vehicles - Electric vehicle conductive charging sys-tem - Part 1: General requirements (IEC 61851-1:2010)”; German version EN 61851-1:2011

The operator is responsible for specifying the inspection interval.

Installation location

  • The national laws, directives, ordinances, and regulations for the installation and oper-ation of electrical equipment which are valid at the installation location must be ob-served.
  • The charging technology set is intended for stationary use.
  • The charging technology set is designed for fixed mounting in a suitable housing.
  • The charging technology set must be freely accessible at all times in case of emergen-cy, for operation, and for maintenance work.

EV-SET-T2AC-BAS-RCM1-20AC5MES 8 PHOENIX CONTACT 107839_en_00

  • Protect the charging technology set from direct sunlight.
  • Electromagnetic compatibility: this product is suitable for environment B. For the re-quirements for environments A and B, refer to the standard DIN EN 61439-1 as well as the following standards:
    • Environment A (industrial environments): EN 61000-6-2:2005 + AC: 2005
    • Environment B (residential, commercial, and light-industrial environments): EN 61000-6-4:2007 + A1: 2011

Only operate the charging technology set in the approved environment.

General 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. Observe the rules in the specified order:

  1. Disconnect safely.
  2. Ensure power cannot be switched on again.
  3. Verify safe isolation from the supply.
  4. Ground and short circuit.
  5. Cover or safeguard adjacent live parts.

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

Important: read the instruction manual carefully before mounting, installing, and starting up the charging technology set. Pay particular attention to the safety notes. Keep the in-struction manual and circuit diagram in a safe place for later use. Make sure you always use the latest documentation for the individual components. The documentation can be downloaded at phoenixcontact.net/products.

WARNING: Dangerous contact voltage!
  • Any work on the charging technology set may only be carried out by qualified special-ist personnel who are familiar with the necessary safety precautions.
  • The charging technology set or parts thereof are live. Maintenance work on live equipment may only be carried out by qualified specialist personnel who are familiar with the necessary safety precautions.
  • Before working on the charging technology set, disconnect the power.
  • During installation, observe the instructions on grounding in “Starting up the charging technology set” on page 22. The operator must ensure that suitable safety precau-tions have been taken.
DANGER: Faulty insulation

Risk of electric shock.

  • Only use cables that satisfy the specified installation requirements regarding voltage, current, insulation material, load-carrying capacity, etc.

Transport

107839_en_00 PHOENIX CONTACT 93 Transport

  • Observe the humidity specifications and the temperature range specified for transport (see Section “Technical data” on page 12).
  • Secure the charging technology set during transport. The same applies when relocat-ing, moving or returning the equipment. Internal transport is only permitted if the trans-ported goods are adequately secured against slipping and falling.
  • Never climb onto the devices or packaging.
  • Protect devices and packaging against damage.
  • When transporting the equipment or storing it tempora