sgm pilotbox technical introduction€¦ · (home, hotel …) and public park decks any number of...

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July 2011 – Anna Wels

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SGM PilotBox

Technical Introduction:

Proximity, pilot signal, typical charging cycle

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Application

Product image

Terminal overview

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SGM PilotBox | Flexibly usable control and charging unit

Constitutes the product family of the

Smart Grid Modules

SGM PilotBox is the central control

and charging unit in wall boxes and

charging stations (EVSE) for electric

vehicles (PEVs)

Usable very flexible

Stand alone in private garages

(home, hotel …) and public park

decks

Any number of SGM PilotBoxes

combined with control logic and

communication (INSYS MoRoS,

PLC …) for "intelligent charging"

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SGM PilotBox | Mode 3 according to IEC 61851 and special

functions

All the functions in the Mode 3 charging

method in compliance with IEC 61851 and

VDE-AR-E 2623-2-2

and in addition:

Integrated emergency power supply opens

connector locking upon power failure

Provision of the operating voltage for 12 V

actuators

Comfort functions in combination

with external control logic/PLC

and/or data communication

Operational reliability

Emeregency opening of the charging

connector locking

Safety shutdown in case of a failure

Individual configuration

Easy installation and service

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SGM PilotBox | Application example 1

SGM PilotBox

EVSE

Electrical Vehicle Supply

Equipment;

Charging station PEV

Plug-In Electric Vehicle

Housing for charging station:

Column, wall box, distribution

or switch cabinet

SGM PilotBox

Power supply unit

RCD and MCB

Load contactor

Charging socket for

Mode 3 acc. to IEC 61851

Incidentals for wiring

and installation

Basic equipment

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"Combined with control logic"


SGM PilotBox Control logic

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"Combined with control logic and communication"


SGM PilotBox

LAN / WAN

Control logic

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"System with master control"


SGM PilotBox SGM PilotBox SGM PilotBox

Master control

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"System with master control and communication"


SGM PilotBox SGM PilotBox SGM PilotBox

Master control

LAN / WAN

Communication

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SGM PilotBox | Product image and terminal overview

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Optional

Key switch

Charging

Local

power distribution network

Release

set max. charging

current act. charging current

limit Charging cable status

Grid

3/N/PE AC 230 V 50 Hz

Grid Contactor

Chargin

g

plug

Charging

station

Electric vehicle

Optional

Key switch

Pilot signal

SGM PilotBox

Feedback

connector

locking

Fan control

Fan feedback

12..24 V DC

Charging

cable

SGM PilotBox | Device list for stand-alone charging station

Connector locking

12..24 V DC and

12 V DC const.

Resistance

encoding

(proximity)

RCD

MCB

Charging

station

Charging

socket

SGM PilotBox

12..24 V DC

Load contactor RCD MCB

Grid

3/N/PE AC 400/230 V

Housing for charging station:

Column, wall box, distribution

or switch cabinet

SGM PilotBox

Power supply unit

RCD and MCB

Load contactor

Charging socket for

Mode 3 acc. to IEC 61851

Incidentals for wiring

and installation

Basic equipment

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Connection examples

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Charging

Local


Release

Set max. charging current

Act. charging current limit

Charging cable status

Grid

3/N/PE AC 400/230 V

Load

contactor

Charging

socket

Charging

station

Electric vehicle

Optional

Key switch

Pilot signal

SGM PilotBox

Feedback

connector

locking

Fan control

Fan feedback

12..24 V DC

Charging

cable

SGM PilotBox | Connection example "Stand-alone" and options

Connector locking

12..24 V DC and

12 V DC const.

Resistance

encoding

(proximity)

RCD MCB

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SGM PilotBox | Connection example "Stand-alone" and options

Optional

Electric

meter

Optional

control

Optional

Data Communication

Charging

Local


Release




Connector locking

12..24 V DC and

12 V DC const.

Grid

3/N/PE AC 400/230 V

Load contactor

Charging

socket

Charging

station

Optional

WAN

Electric vehicle

Optional

Key switch

Pilot signal

SGM PilotBox

Feedback

connector

locking

Fan control

Fan feedback

12..24 V DC

Charging

cable

Resistance

encoding

(proximity)

RCD MCB

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SGM PilotBox | Example with control logic and communication

Electric

meter

Charging

Release




Charging

Connector locking

Feedback

connector

locking

Charging

station

WAN

Local


Grid

3/N/PE AC 400/230 V

Control

Key switch

Pilot signal

Charging

socket

SGM PilotBox

Optional

Data Communication

12..24 V DC

Charging

cable

Electric vehicle

Fan control

Fan feedback

Resistance

encoding

(proximity)

Connector locking

12..24 V DC and

12 V DC const.


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Plug at charging cable

Proximity

Pilot signal, duty cycle

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SGM PilotBox | e-mobility plug

Highest safety with maximum

capacity

Proven in European pilot projects

(Germany, Italy, Netherlands,

Austria and Poland)

German associations BDEW, VDA

and VDE as well as ZVEI have one

common position: The e-Mobility

plug type 2 is the forward-looking

solution for Europe

Source and Copyright:

Mennekes (image) , RWE (text)

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SGM PilotBox | Contacts in charging plug

Safety Proximity:

checks and signals the maximum

capacity of the cable

Control pilot:

enables the communication with the

electric vehicle and fulfills the functions

safety (protective conductor is return

conductor for CP an PP) as well as

limitation and control of the charging

current

Earth: GND, earth (protective

conductor)

Energy transmission Neutral: neutral conductor

L1, L2 and L3:

Phases 1, 2 and 3


Mennekes (image) , RWE (text)

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SGM PilotBox | Why encoding charging cable and proximity?

Charging plug fixture is designed for

63 A

But: a charging cable for 63 A is

very bulky due to weight (1 m cable

5 x 16 mm² is approx.1,6 kg) and

diameter (approx. 30 mm),

therefore: included charging cables e.g. only for

32 A with cable cross-section 4 to

6 mm²;

lines fixed to quick charging stations for

63 A with 16 mm²

Solution: charging cable coding with

its maximum current carrying

capacity by resistance bridge

between

"plug present" contact and PE


Mennekes (figure)

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SGM PilotBox | Pilot signal

Voltage (Vg) from signal generator of the SGM PilotBox

either be a steady state +12 V DC

or a signal with +/-12 V, 1 kHz according to Table A.1 IEC 61581 (if the

EVSE is immediately available for power delivery)

A - Vehicle not connected

B - EVSE can supply power

C - charging process

without ventilation

D - charging process

requires ventilation

State

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SGM PilotBox | Duty cycle (pulse width modulation, PWM)

The SGM PilotBox uses pulse with modulation (PWM) of the pilot signal to

transmit the maximum permissible charging current (6 .. 80 A) to the electric

vehicle.

This value is the lower of the two values from Set_Max_Current and the

maximum current carrying capacity of the charging cable detected using

proximity.

The charging control in the electric vehicle is only responsible for compliance

with this specification.

See IEC 61851, Table A.6 – Maximum current to be drawn by vehicle, p. 37 and http://en.wikipedia.org/wiki/Duty_cycle

50 %

http://en.wikipedia.org/wiki/Duty_cycle

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Typical charging cycle

Signal sequences and conditions of the

inputs and outputs under normal conditions

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Local


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

SGM PilotBox

12..24 V DC

SGM PilotBox | Installed ready to use

Charging

socket

SGM PilotBox installed

and supplied with

operating voltage.

Application

RCD MCB

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Local



Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

SGM PilotBox

12..24 V DC

SGM PilotBox | Customer provision of max. charging current

Charging

socket

SGM PilotBox installed

and supplied with

operating voltage.

Maximum charging current

is set acc. to public utility

or customer boundary

conditions.

Application

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

optional

Key switch SGM PilotBox

12..24 V DC

SGM PilotBox | Release starts proximity and pilot signal

Charging

socket

Resistance

encoding

(proximity)

Release via switch or

hard-wired release input.

Pilot signal

SGM PilotBox generates

and measures pilot signal

+ 12 V.

Proximity

Active detection of the

current carrying capacity

of the charging cable by

the SGM PilotBox.

Step 0

Pilot signal

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

optional


12..24 V DC

SGM PilotBox | Proximity and pilot signal active

Charging

socket

Resistance

encoding

(proximity)

Vehicle not connected.

Pilot signal

SGM PilotBox generates

and measures pilot signal

+ 12 V.

Proximity

Active detection of the

current carrying capacity

of the charging cable by

the SGM PilotBox.

Step 1 - Status A

Pilot signal

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Connect charging cable

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Charging cable is

connected to PEV and

EVSE.

SGM PilotBox

… detects current carrying

capacity of the charging

cable using the proximity

resistance.

… detects Status B using

+ 9 V pilot signal.

Step 2 - Status B

Pilot signal

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Charging station is able to supply power

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

The charging station could

supply power on request

now.

SGM PilotBox

… indicates the max.

current to the electric

vehicle using pulse width

modulation (PWM) of the

pilot signal, that can be

"drawn" from the grid by

the charging control.

Step 3 - Status B

Pilot signal

RCD MCB

16 A

32 A

16 A

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Electric vehicle requests charging

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Electric vehicle

… closes switch S 2 and

signals its readiness for

power taking to the SGM

PilotBox.

SGM PilotBox

… detects Status C using

+ 6 V pilot signal or Status

D (lead accumulator) using

+ 3 V pilot signal.

Step 4 a - Status B C

Pilot signal

RCD MCB

S 2

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Ventilation control for Status D (lead accumulator)

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… detects Status D using

+ 3 V pilot signal.

… controls ventilation.

… checks whether

"ventilation feedback" is

active; if feedback is

inactive, the load contactor

control will be blocked.

Step 4 b - Status B D

Pilot signal

Fan control

Fan feedback

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | CHarging connector locking

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… controls actuator for

charging connector locking.

… detects status of charging

connector locking.

… signals status of charging

connector locking.

…

Step 5.1 - Status C

Pilot signal Connector locking

12..24 V DC and

12 V DC const.

Feedback

connector

locking

Status charging connector

locking

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Connector locking and load contactor control

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… controls actuator for

charging connector locking.

… detects status of charging

connector locking.

… signals status of charging

connector locking.

… controls the load

contactor (closing).

Step 5.2 - Status C


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Charging

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Vehicle may charge on demand

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Electric vehicle

…may take not more than

the charging current that is

specified by the SGM

PilotBox via duty cycle

(PWM in pilot signal).

External RCD and MCB

… monitor charging and

fault current.

… cut-off immediately in

case of a failure.

Step 6 - Status C


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Charging

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | External request for power reduction

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… indicates new value via

duty cycle (PWM in pilot

signal) to the electric

vehicle.

Electric vehicle

… reduces maximum

current demand to the new

value.

Step 7 - Status C


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Charging

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Vehicle determines end of the charging process

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Electric vehicle

… does not take charging

current any more.

… keeps switch S 2 still

closed!

… could take charging

current later again.

Step 8 - Status C


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Charging

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Load contactor

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Vehicle requests cut-off of the charging voltage

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Electric vehicle

… opens the switch S 2 in

the electric vehicle

S 2 is controlled by the

charging control of the

vehicle or manual

intervention of the driver

Step 9 - Status C B


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Charging

RCD MCB

S 2

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Local


Release


Grid

3/N/PE AC 400/230 V

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Cut-off of the charging voltage

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… opens load contactor.

… is Status D previous:

shut-off ventilation

… charging plug still

remians locked!

Step 10 - Status B


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking

Load contactor

Charging

RCD MCB

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Local


Release


Grid

3/N/PE AC 400/230 V

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Actuator control for connector unlocking

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

SGM PilotBox

… detects the removal of

the charging cable from

the vehicle using the

12 V DC signal.

… controls the actuator for

opening the charging

connector locking.

… monitors interlock

feedback.

Step 11 - Status B A


12..24 V DC and

12 V DC const.

Feedback

connector

locking


locking


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Local


Release


Grid

3/N/PE AC 400/230 V

Charging station

Electric vehicle

optional


12..24 V DC

SGM PilotBox | Charging cable can be unplugged

Charging

socket

Charging

cable

Resistance

encoding

(proximity)

Charging connector

locking is open.

Charging cable can be

unplugged from the

charging socket at the

charging station.

Step 12 - Status A

Pilot signal


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Pilot signal sequence for typical charging cycle

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SGM PilotBox | Typical charging cycle for normal conditions

Pilot signal

Ua [V]

+ 12

+ 9

+ 6

+ 3

0

-12

A

B

C

D

Vehicle

S2

On

Off

AC supply

from EVSE

On

Off

AC current

drawn max.

Imax2

Imax1

1

2

3

4

6 7

9

5

8

10

11

Plugged

Unplugged

Cable

assembly

7 8

9

12

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SGM PilotBox | Typical charging cycle for normal conditions

Pilot signal

Ua [V]

+ 12

+ 9

+ 6

+ 3

0

-12

A

B

C

D

Vehicle

S2

On

Off

AC supply

from EVSE

On

Off

AC current

drawn max.

1

2

3

4

6 7

9

5

8

10

11

Plugged

Unplugged

Cable

assembly

7 8

9

12

Imax2

Imax1

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Operational Reliability

Compliance with the Standards

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Immediate shutdown

in case of one of these failures:

Fault current in protective conductor

Invalid level of the pilot signal

Faulty connector locking

Invalid values of the resistance coding

(proximity)

Withdrawal of charging release

Ventilation failure

Emergency opening of the connector locking

upon power failure

SGM-PilotBox | Highest possible operational reliability

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Compliance with the Standards

Compliant with the latest IEC 61851 or

VDE application guide VDE-AR-E 2623-2-2

EMC Directive 2004/108/EC

Low Voltage Directive 2006/95/EC

SGM-PilotBox | International standard compliant

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Thank You!

Your direct way for contacting us:

INSYS icom

INSYS MICROELECTRONICS GmbH

Waffnergasse 8, D-93047 Regensburg

Phone +49 941 58 692 0

Fax +49 (0) 941 58 692 45

[email protected]

www.insys-icom.com

INSYS Energy | Technologies for the intelligent supply

sgm pilotbox technical introduction€¦ · (home, hotel …) and public park decks any number of...

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