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Intelligent electrical safety for the mobile future
In nearly 70 years, we have learned to think ahead in electrical installation to the range of different charging
a strategic, future-oriented manner and to deal today stations and into the vehicle.
with what the customer will need tomorrow. Innovative
solutions and services, unique know-how and global As the global market and technology leader, this is
expertise when it comes to electrical safety provide a underlined in our 5forU quality promise:
response to the mobile challenges of the future - from Five-year guarantee on our products.
Safety while d
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V On-Boa
icle H rd Ne
Veh two
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Page 3
Page 6
Page 8
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AC
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Saf g
ety while chargin
In building installations
The requirements for electrical safety in buildings are
defined in detail in the DIN VDE 0100 series of standards.
To make sure that electric vehicles (EV) can be charged
safely and reliably, both the necessary protective
measures required for the building and those required
for new installations must be complied with and
the system set up in accordance with the normative
requirements for the charging process.
3
Electrical safety for the on-board network for
electric vehicles - insulation monitoring
Major characteristics:
n Universal for Voltage Class B systems
AC/DC 0…1000 V IR155
AC/DC 0…600 V iso165C ISOMETER® IR155
n Patented measurement method for preventative
detection of insulation faults 0…10 MΩ
n Additional safety via automatic self-test Overview of important standards:
n Permanent monitoring of earth connection to n ISO 6469-3:2011-12
4
Application examples
© www.bender.de RESS
Inverter
= M
L1 F
I∆n DC ≥ 6 mA (option)
= Air conditioning
PFC
N other loads
=
CP
Control pilot AC on-board
function charger
PE with galvanic IMD 14 V on-board
separation (option) network
= (galvanically
isolated)
RTyre
Insulation monitoring in an electric vehicle (EV) with an AC on-board charger with galvanic separation
5
Electrical safety for DC charging stations
– Insulation monitoring
Application examples
TN-C-S System
distribution branch
power source system installation circuit input DC charging station charging cable
Application example
L1
L2
L3 Mode 4 IT system
IEC 60364-7-722
N I∆n DC ≥ 6 mA (Option)
PEN
PE
contactor
F
DC+
F
RB
DC-
RCD
Typ A isolating
transformer IMD
earthing at the Control CP
power source pilot CP
function
PE
RPE
earthing in the
RA
distribution system
RAE
6
Major characteristics:
Overview of important standards:
n Insulation monitoring for unearthed
n DIN EN 61851-23 (VDE 0122-
charging stations AC 0…793 V/DC 0…1000 V
2-3):2014-11 (IT systems)
Electric vehicle conductive
n Two response values that can be set separately
charging system
n Basic parameterisation 100/500 kΩ
Part 23: d.c. electric vehicle
charging station n Network/earth connection monitoring
(IEC 69/206/CD:2011) n LEDs for operation, Alarm 1, Alarm 2
vehicle vehicle
inlet connector battery electric vehicle (BEV)
DC contactor RESS
F Inverter
DC + F V = M
DC - F
L
I∆n DC ≥ 6 mA (option)
= Air conditioning
PFC
other loads
=
N
Control pilot AC on-board
CP charger
function
PP with galvanic IMD 14 V on-board
separation (option) network
PE
= (galvanically
isolated)
RTyre
7
Electrical safety for AC charging
Monitoring of direct fault currents I Δn DC ≥ 6 mA
Electrical equipment of electric vehicles – Electric vehicle n Permanent connection monitoring of measuring
conductive charging system – current transformer
Part 1: General requirements; section 7.6 n LEDs for operation and alarm
“The charging system must limit the introduction of n Internal test button
direct currents and non-sinusoidal currents which n Alarm relay with 1 N/C contact
could affect the functionality of residual current
n Precise measurement by means of digital
devices (RCD)...” (Translation: Bender GmbH & Co KG)
measurement method
n I EC 60364-7-722:2015 (Power supply of electric vehicles
n Insensitive to load currents thanks to full magnetic
722.531.2.101 shielding
"Residual current protective devices (RCD)
n With optional analogue measurement output
• A separate type A residual current device (RCD)
n Cost-oriented solution in connection with fault
IΔn ≤ 30 mA, min. for each connection point
current protective device (RCD type A)
• Suitable measures must be taken for direct fault
currents IΔn DC ≥ 6 mA."
(Translation: Bender GmbH & Co KG) Other device functions:
n 2-channel residual current measurement
IΔn DC ≥ 6 mA
8
Application example: Compact and future-proof:
The RCBM420EC residual current The RCMB121 residual current
monitor provides various options for monitor already fulfils the
integration into the power supply requirements of the new draft of the
system for electric vehicles. standard IEC 62752 (IC-CPD). Due to
the compact structure, in addition to
In an AC EV charging station, its use in a IC-CPD (charging mode
this means that, for example, the 2) it is suitable for use in wall boxes
charging switch can be connected, (charging mode 3). The RCMB121
plus the relays for the fault current complies with the requirements of
circuit in the IC-CPD. It can also be IEC 60364-7-722:2015. Residual current monitoring module
used in an electric vehicle (EV). RCMB104
Start
Stop User interface
Switch
IC-CPD * Switch
Control Communication
Control pilot Overcurrent
pilot protection Overcurrent
communication Vehicle
communication protection
- *)
Monitoring I∆n DC ≥ 6 mA Loads
Electronic
*)
I∆n DC ≥ 6 mA
RCMB420EC
Power RCMB420EC
RCD Typ A supply
I∆n RCD Typ A
AC ≥ 30 mA
I∆n Overvoltage
Überspannung
RCMB121
protection Control Overvoltage
DC ≥ 6 mA Überspannung
Monitoring protection
Diagnostic
*) option Remote Energy measurement
maintenance Billing
kWh
8888
RCMB121-2
Connection to
the supply Connection to the *) option
network supply network Connection to the
Communication supply network
9
Electrical safety for AC charging
Monitoring of direct fault currents I Δn DC ≥ 6 mA
DC contactor RESS
DC + F Inverter
DC - F V = M
L1 F
= Air
PFC
N conditioning
= other loads
CP
Control pilot AC on-board
PP charger system
function
PE with galvanic IMD 14 V on-board
separation (option) network
= (galvanically
isolated)
RTyre
10
AC charging considering the electrical safety
requirements
The Charge Controller CC612 combines the electrical safety requirements of AC charging
points with the vehicle charging requirements.
11
Electrical safety begins with the electrical installation
The safe, reliable charging of electric vehicles (EV) is directly linked to electrical safety in building installations. In earthed
systems (TN/TT systems) the focus is on the use of residual current devices (RCD) and in unearthed power supply
systems (IT systems) it is on the use of insulation monitoring devices (IMD) or insulation fault location systems (IFLS).
n Regular maintenance and repairs with, n DIN VDE 0100-722 VDE 0100-722:2012-10
12
Possible network designs based on DIN VDE 0100-100 (VDE 0100-100): 2009-06 for charging
L1 L1 L1
L2 L2 L2
L3 L3 L3
N N N
PEN
PE PE PE
RB RB
TN-C-S system 3-phase, 4 conductors, TT system with earthed protective IT system where the exposed
PEN conductor at the point of supply conductors and N conductors conductive parts (of electrical
divided into PE and N conductors throughout the whole system equipment) have separate connections
to earth
In all three systems, an earthing system must be installed which complies with DIN VDE 0100-410 (VDE 0100-410):
2007-06, Chapter 411.3.1 Protective earthing and equipotential bonding.
n Is the connected power in the building sufficient or does it need to be increased?
n Is a residual current device (RCD) installed in the charging current circuit distributor?
13
Overview of charging methods
14
RCD
RCD
RCD
IMD
Control Pilot Power Line Communication, Control Wireless Power Line Communication
Pilot (PWM), RFID, GSM, 3G/4G
Building installation
min. RCD type A IΔn ≤ 30 mA , if IΔn DC ≥ 6 mA RCD type B or type A plus suitable measures in charging point
– – – –
Charging point/Charging station
min. RCD type A IΔn ≤ 30 mA – IMD
if IΔn DC ≥ 6 mA RCD type B or other measure (e.g. RCMB420EC)
DIN EN 61851-21:2011-05 (VDE 0122-1:2011-05) DIN EN 61851-23:2014 (VDE 0122-2-
E DIN EN 61851-22 (VDE 0122-2-2):2011-04 (IEC 69/184/CD:2010) 3:2014-11)
DIN EN 61557-8:2013-08 (VDE 0413-
8:2013-08)
15
Overview of charging modes and protective measures
Electric vehicles (EV) are normally loaded at different times, in different places or different feed points, requiring different
energy input. In order to provide the necessary safety and charging energy to match the demand, four different charging
modes are defined in IEC 61851-1:2010-12.
Mode 1
acc. to
E DIN VDE 0100-722:
2011-09
acc. to
AC charging
I II III
main distribution board charging station plug/
socket
semi-public/public chaging stations
*)
F F
acc. to
DIN VDE 0100-410: charging
2007-06 switch Communication
16
n Mode 1: Uncontrolled charging
• AC charging at a socket 1ph/3ph (Schuko, CEE)
• Max. charging current: 16 A/11 kW
IV V VI
charging cable plug/ Electrical vehicle (EV) • Charger built into the vehicle
socket-outlet • No communication with the vehicle
• Locking mechanism of the plug and socket-outlet
in the vehicle
• This is not recommended, as it is not guaranteed
that a residual current device (RCD) is included in
I∆n DC≥ 6 mA *)
the building installation.
(Option)
IMD
n Mode 2: Uncontrolled charging
*) DC • AC charging at a socket 1ph/3ph (Schuko, CEE)
IC-CPD • Max. charging current: 32 A/22 kW
CP Control pilot function
*)
• Charger built into the vehicle
• Protective device/pilot function in the cable (IC-CPD)
CP • Locking mechanism of the plug and socket-outlet
Communication
in the vehicle
I∆n DC≥ 6 mA *)
(Option) n
IMD Mode 4: Controlled charging
• DC charging on type-tested DC charging stations
*) DC for electric vehicles
CP Control pilot function • Max. charging power: DC low max. 38 kW/DC high
170 kW (charging voltage and current depend on
system)
• Monitoring and protective device/pilot function
*) presently discussed
integrated into charging station
• Locking mechanism of the plug and socket-outlet
in the vehicle
• Charging cable built into the charging station
17
Monitoring of direct fault currents I Δn DC ≥ 6 mA
20
-10
If direct fault currents IΔn DC ≥ 6 mA occur, e.g. during
charging, then both the response time and the response -20
Suitable measures could be: Detection of Electrical equipment of electric vehicles – Electric
IΔn DC ≥ 6 mA using RCMB420EC and therefore vehicle conductive charging system –
Part 1: General requirements; section 7.6
n Controlling the charging switch in a charging station "The charging system must limit the introduction of
(Mode 3) direct currents and non-sinusoidal currents which
n Controlling the relay in an IC-CPD could affect the functionality of residual current
device (RCD)..." (Translation: Bender GmbH & Co KG).
n Controlling the vehicle electronics
type A residual current device (RCD) in the building voltage electrical installations
installation. "722.531.2.101 Residual current devices (RCD)
• A separate type A residual current device (RCD)
Note IΔn ≤ 30 mA, min. for each connection
The use of a detection system for IΔn DC ≥ 6 mA with
• When direct fault currents IΔn DC ≥ 6 mA occur,
RCMB420EC also makes a residual current device
suitable measures must be taken."
(RCD) necessary in accordance with DIN VDE 0100. It
protects the type A residual current device (RCD) against
malfunction.
18
Typ A RCD 30 mA (in the case of AC: 0,5... 1 x I∆n)
C1 C2 C3
10000
duration of current flow
a b
5000
AC - 4 - 1
AC - 4 - 2
2000
AC - 4 - 3
t (ms)
1000
disconnection time
acc. to IEC 60364-4-41
500
400
TN 120 ... ≤ 230 V AC-1 AC-2 AC-3 AC-4
200
TN 230 ... ≤ 400 V
100
TN > 400 V
50
20
10
0,1 0,2 0,5 1 2 5 10 20 30 50 100 200 500 1000 2000 5000 10000
threshold for releasing current threshold for mA
perception 3,5 mA fibrillation shock current IB
touch current
Diagram: Time/current zones of effects of AC currents (15 to 100 Hz)on persons for a current path corrresponding from left
hand to feet in accordance with IEC and with disconnection times as defined in DIN VDE 0100-410:2007 and the normal
response curves for a residual current device (RCD).
19
2164en / 09.2017 / pdf / © Bender GmbH & Co. KG, Germany – Subject to change! The specified standards take into account the edition valid until 09.2017 unless otherwise indicated.