EVSE Testing

AGENDA

1. Why Test EV Charge Stations
2. What Tests
3. A1532 XA Adapter
4. Metrel Complete Solution with Autotsequence
5. EVSE Test Report
6. Other Metrel Products

Why Test EV Charge Stations ❓

AUSTRALIAN STANDARDS and Regulations (state specific):

AS NZS 3000:2018 Wiring Rules:

Section P: Guidance for Installation and location of EV Socket Outlets and Charging Stations.

AS/NZS 3017 (commissioning tests), 3019 (periodic verification), 3760 (PAT)

RCD Protection IEC 62955 AS IEC 61851

PERIODIC VERIFICATION AS3000 APPENDIX P

Why test?

• The presence of possible faults cannot be seen or smelt.
• Verify correct operation of equipment (charger & cables)

Image depicting a severely burnt electric vehicle, likely due to a fire, highlighting the potential dangers of faulty charging equipment.

What tests?

• PE conductor continuity
• Insulation resistance
• Loop impedance
• Line impedance
• RCD Tripout Time and Tripout Current

Measuring Methods

A 1532 XA EVSEAdapter

"Open" the EVSE for safe electrical testing (with MI 3155 or MI 3152)

• Check the electrical parameters on the output of EVSE (Voltage, loop, line)
• RCD testing (30 mA AC and 6 mA DC type B)
• EVSE insulation check

Diagram illustrating the A 1532 XA EVSEAdapter connections, showing ports for L1, L2, L3, N, PE, EV, PEop, CPsh, and indicating connections to a tester and the EVSE.

A1532XA – Functional Tests

Proximity Pilot (PP): simulation of EV cable presence and charging current. (weakest link)

Control Pilot (CP): simulation of electric vehicle status.

Schematic showing the A1532XA device with Proximity Pilot (PP) and Control Pilot (CP) ports, and a simplified circuit diagram of an EV charge point, EV charge cable, and electric vehicle.

Error Simulations and Load Test - A1532XA

Error Simulation:

• a) PE open
• b) Diode short
• c) CP Short

Load Test up to 13 A:

• a) Single phase from socket
• b) 3 Phase from banana sockets

Close-up view of the A1532XA device's front panel, highlighting the PEop and CPsh buttons used for error simulation, along with rotary selectors for PP and CP states.

The METREL complete solution

MI 3155 / MI 3152 ➕ Funct. test ➕ Auto Sequence ➕ A 1532 ➡️ EVSE report

Diagram showing the Metrel complete solution setup: two Metrel testers (MI 3155/MI 3152), an A 1532 adapter, connected to an EVSE, leading to an EVSE report.

Advantage of Autosequence

➕ Auto Sequences®

• Series of test (functional and electrical) simplifies testing
• Instructions between steps.
• Ensure compliance with standards (pass limits set to standards).

Images of Metrel testers (MI 3155, MI 3152) and screenshots of the Auto Sequences software interface.

Test procedure: Start Auto Sequence® & run Functional test

EVSE 3p No Vent trip

Check System / Fuse / RCD parameters.

Plug EV adapter into the charging station.

PP state knob set to the desired loading current.

CP state knob setting follow ABCE positions.

Fill-in status checkboxes of the inspection.

Inspection

Functional EVSE

CP states:

• A-EVSE in idle state
• B-EV detected, EVSE does not charge
• C-EV is charged
• E-pilot error, charging interrupted

Diagram illustrating the connection of the A 1532 adapter to an EVSE, with arrows indicating PP and CP signals.

Test procedure: Auto Sequence®: energized system (1/2)

1. A 1532: set CP state = C & connect test leads.
2. MI 3155: Voltage test
3. MI 3155: Z auto test

Series of diagrams showing the test setup for an energized system, with an A 1532 adapter connected to an EVSE, and test leads from an MI 3155 tester. The process is repeated for each phase.

Test procedure: Auto Sequence®: energized system (2/2)

1. A 1532: Set CP state = C and Leave L test lead on L3 terminal.
2. MI 3155: RCD Auto test ➡️ Type A + Type B = Type EV RCD

Diagram showing the test setup for an energized system, with an A 1532 adapter connected to an EVSE, and test leads from an MI 3155 tester.

Test procedure: Auto Sequence®: non-energized system

1. A 1532: set CP state = B & leave L test lead on L3 terminal.
2. MI 3155: R iso test ➡️ L3-PE

Repeat R iso test for:

• L2-PE
• L1-PE
• N-PE

Series of diagrams showing the test setup for a non-energized system, with an A 1532 adapter connected to an EVSE, and test leads from an MI 3155 tester.

Test procedure: Create EVSE report

A sample EVSE Test Report document, displaying sections for visual inspections, single tests, voltage, Z auto, and other parameters.

Other Metrel Products

Image of the Metrel InstaltestCombo MI3125BT tester.

Low Cost Tester with 6mA DC RCD test

A 1632 eMobilityAnalyser

Basic features like the A 1532, plus:

• Mode 2 charging testing
• Mode 3 cable testing
• Different output errors (PE open, Diode short)
• Input errors
• EVSE monitor with A 1632
• Diagnostic test EVSE
• Bluetooth connection
• Remote operation with Android app

Image of the Metrel A 1632 eMobilityAnalyser and its interface displaying diagnostic test results.

A 1631 EV monitoring cable

Monitoring during a.c. EV charging with up to 32 A EVSE:

• CP signal communication monitoring during charging;*
• PP resistance;
• Current;
• Voltage;
• Current and voltage verification with MI 2883 Energy Master or MI 2884 Energy Master XA;
• Possible to simulate external load (up to 13 A) via banana plugs and verify EVSE counters.

Image of the Metrel A 1631 EV monitoring cable, showing its robust construction and connectors.

Instrument Comparison

Diagrams illustrating EVSE testing scenarios, including PP/CP states, load testing, input/output errors, and diagnostic test setups.

Diagnostic Tests

Graph illustrating different EVSE states (A, B, C, D, E) with corresponding peak voltage, EV connection status, charging possibility, and notes.

Screenshots of the Metrel tester interface showing diagnostic test results for EVSE, including CP states and error messages.

NEW EV TESTER - MI 3132 EV Tester

MEASURING FUNCTIONS

• Insulation measurements according to UN ECE R100 and ISO 6469-3 with own REESS as DC voltage source.
• Discharge time measurement.
• Insulation resistance with DC voltage from 50 V to 1500V.
• DC voltage.
• TRMS voltage and frequency measurements.
• Four wire Micro Ohm measurements with 2 A DC test current.
• Low Ohm measurements with 7 mA and 200 mA DC test current.
• Visual safety and functional inspections.

KEY FEATURES

• Insulation resistance measuring according to UN ECE R100 measuring using internal DC source.
• Performing accurate four wire measurements with quality Kelvin clamps and up to 2 A measuring current.
• Settable duration and current direction (unidirectional or bidirectional).
• Insulation range: wide range of insulation test voltages from 50 V to 1500 V, resistance measuring range up to 3 GΩ.
• Overvoltage category 1000 V CAT II, 600 V CAT III.
• 4.3" colour LCD display with touch screen.
• Programmable AUTO SEQUENCES™.
• High degree of protection.
• DC resistance measurements.
• Support for single or automated measurements.
• Built-in charger and rechargeable Li-Ion batteries as standard accessory.
• BT communication with PC, Android tablets and smart phones via built-in BT module.
• PC SW Metrel ES Manager for measurement pre and post processing, preparation of the test structure, result download, tree-view, table view and graphical view, storing and printing.

STANDARDS

• Functionality: UN ECE R100, ISO 6469-3
• Electromagnetic compatibility: EN 61326
• Safety: EN 61010-1, EN 61010-2-030, EN 61010-2-032, EN 61010-031

APPLICATION

• Electric vehicle service and maintenance.
• In services, workshops and electric vehicle production plants.
• Electric vehicle after crash safety check.
• Electric car cables and components test.

Image of the Metrel MI 3132 EV Tester.

EVSE testing examples

Photograph of a technician performing EVSE testing using Metrel equipment (A 1532 adapter and a Metrel tester).