Title www.megger.com2CAR CHARGERS FOR ELECTRIC VEHICLES:A STEP-BY-STEP GUIDE TO AUTOMATED TESTING2CAR CHARGERS FOR ELECTRIC VEHICLES: A STEP-BY-STEP GUIDE TO AUTOMATED TESTING WWW.MEGGER.COM ■This guide refers only to chargers for electrically propelled vehicles – that is, electric vehicles (EVs) and hybrids driven by an electric motor powered by a high voltage battery. It does not cover the charging of low voltage batteries in vehicles which use other types of motive power, such as petrol or diesel engines. ■The equipment used for charging electric vehicles is usually called a ‘car charger’, an ‘EV charger’ or an ‘EV charge point’. Strictly speaking, none of these descriptions are correct, as the charger itself is frequently within the vehicle. A more accurate description is ‘electric vehicle supply equipment’ or EVSE. However, this description is rarely used other than in standards and regulations, so to make this document easier to read and understand, the description ‘car charger’ is used throughout. ■Car chargers are usually classified as belonging to one of four ‘Modes’. Mode 1, 2 and 3 car chargers supply AC to the vehicle and the AC is converted to DC in the vehicle. Mode 4 car chargers, which are used for high-power fast charging, supply DC to the vehicle. Mode 4 is the only type of car charger where the charger itself is not in the vehicle. ■Mode 1 charging is achieved by connecting a domestic power outlet to the car with a simple lead, essentially an extension lead. Mode 1 charging does not incorporate the safety features of Mode 2 or 3. The safety of this charging mode relies entirely on the safety of the electrical installation, as there is no additional functionality. This mode is becoming unusual and is illegal in many countries. Where it is used, however, the charging circuit should be tested in the same way as any other circuit in the electrical installation – no additional tests are possible. ■Mode 2 car chargers are simply in-line modules that incorporate basic control and protection capabilities. Car manufacturers commonly provide them for charging vehicles from a standard domestic electrical outlet. ■Mode 3 car chargers are currently the most common type. They are fixed items of equipment, often attached to a wall or a free standing post, and they provide a single- or three-phase AC supply to the vehicle. This guide is mainly concerned with testing Mode 3 car chargers.IntroductionThe number of electric vehicles (EVs) in use is increasing rapidly in almost every country, resulting in a corresponding increase in the need for safe facilities to recharge their batteries. Providing these facilities is an excellent and growing business opportunity for electrical contractors who are competent in car charger installation, commissioning and testing. Fortunately, much of the work involved is very similar to that needed when carrying out other types of electrical installation. This guide is intended to ‘fill the gaps’, particularly in relation to testing. Before proceeding, there are a few points that need to be explained:
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